CN113043704A - Double-layer composite floor and preparation method thereof - Google Patents

Double-layer composite floor and preparation method thereof Download PDF

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Publication number
CN113043704A
CN113043704A CN202110410427.9A CN202110410427A CN113043704A CN 113043704 A CN113043704 A CN 113043704A CN 202110410427 A CN202110410427 A CN 202110410427A CN 113043704 A CN113043704 A CN 113043704A
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CN
China
Prior art keywords
layer
hard
plate
section
extrusion
Prior art date
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Pending
Application number
CN202110410427.9A
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Chinese (zh)
Inventor
唐道远
吴光荣
邓梦德
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Anhui Sentai Wpc Group Co ltd
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Anhui Sentai Wpc Group Co ltd
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Publication date
Application filed by Anhui Sentai Wpc Group Co ltd filed Critical Anhui Sentai Wpc Group Co ltd
Priority to CN202110410427.9A priority Critical patent/CN113043704A/en
Priority to AU2021102069A priority patent/AU2021102069A4/en
Priority to DE202021102329.5U priority patent/DE202021102329U1/en
Publication of CN113043704A publication Critical patent/CN113043704A/en
Pending legal-status Critical Current

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Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Architecture (AREA)
  • Manufacturing & Machinery (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Extrusion Moulding Of Plastics Or The Like (AREA)
  • Laminated Bodies (AREA)
  • Molding Of Porous Articles (AREA)

Abstract

The invention relates to a floor, in particular to a double-layer composite floor and a preparation method thereof; belongs to the technical field of floor manufacture. The floor board comprises a hard core layer and an elastic surface layer, wherein the elastic surface layer wraps and covers the hard core layer at least on the upper surface and partial side surface of the floor board; and a matching structure is formed between the hard core layer and the elastic surface layer; the fitting structure comprises a plurality of unit pieces formed on the surface of the hard core layer and a plurality of corresponding pieces formed on the surface of the elastic surface layer; the unit pieces are strip-shaped structures with convex or concave sections arranged along the length direction of the floor. According to the invention, the matching structure is arranged between the elastic surface layer and the hard foaming core layer, so that the elastic surface layer firmly covers the hard foaming core layer, and the elastic foaming core layer has the advantages of the hard foaming core layer and the elastic surface layer, and has high compressive strength and good surface contact property.

Description

Double-layer composite floor and preparation method thereof
Technical Field
The invention relates to a floor, in particular to a double-layer composite floor and a preparation method thereof; belongs to the technical field of floor manufacture.
Background
Elastomers such as rubber, synthetic rubber, thermoplastic elastomers have good tactile sensation, and have the characteristics of softness and good elasticity. This makes the panel with elastomeric material surface have incomparable advantage in the aspect of decoration compared with other macromolecular material.
The patent application document with the international publication number of WO 2018/154287A 1 discloses a low-heat-absorption flame-retardant polyurethane wood-like material, and a polyurethane board prepared from the low-heat-absorption flame-retardant polyurethane wood-like material has the characteristics of flame retardance of a surface layer, low heat absorption, antibiosis and soft touch. But the material belongs to a polyurethane foaming material, when the material is used as a floor, the bending strength of a polyurethane plate is low, and the material cost is high; meanwhile, because polyurethane is a flammable material, a large amount of flame retardant is required to be added, so that the use requirement can be met.
Disclosure of Invention
The present invention is to solve the above problems, and thus provides a double-layered composite floor.
The technical scheme for solving the problems is as follows:
a double-layer composite floor comprises a hard core layer with Shore hardness of more than 80HD and an elastic surface layer with Shore hardness of less than 40HD, wherein the elastic surface layer covers the hard core layer on the upper surface and at least partial side surface of the floor; a matching structure is arranged between the elastic surface layer and the hard core layer and comprises a plurality of unit pieces formed on the surface of the hard core layer and a plurality of corresponding pieces formed on the surface of the elastic surface layer; the unit pieces are strip-shaped structures which are arranged along the length direction of the floor and have convex or groove-shaped sections;
when the section of the unit piece is in a convex shape, the corresponding piece is a convex matching part which wraps the convex and has a groove shape in section;
when the section of the unit piece is in a groove shape, the corresponding piece is a groove matching part which is embedded in the groove and has a convex section;
the material of the elastic surface layer is selected from one or more of natural rubber, synthetic rubber or thermoplastic elastomer;
the hard core layer is selected from one of a metal section, a wood-plastic hot extrusion solid plate, a wood-plastic hot extrusion hollow plate, a hard foaming self-skinning plate, a hard foaming co-extrusion coating plate and a hard foaming co-extrusion coating reinforced plate.
In the technical scheme of the invention, the elastic surface layer and the hard core layer are connected through a matching structure, so that the elastic surface layer and the hard core layer are not required to have good compatibility in material selection, and the selection range of the material can be remarkably expanded. The hard core layer is made of materials with Shore hardness of more than 80HD, such as polyethylene, polyethylene mixed with wood powder, polyvinyl chloride mixed with wood powder or stone powder, and common metals. Meanwhile, in order to reduce the overall weight of the floor, the hard core layer can be made into a hollow structure, or the hard core layer can be made into a hard foaming filling body. Furthermore, the hard core layer can be made of polyethylene wood-plastic materials with hollow structures, hard polyvinyl chloride foaming materials and metal profiles with hollow structures. Furthermore, the hard core layer is selected from one of an aluminum alloy section, a wood-plastic hot extrusion solid plate, a wood-plastic hot extrusion hollow plate, a hard foaming self-skinning plate, a hard foaming co-extrusion coating plate and a hard foaming co-extrusion coating reinforced plate.
The elastic surface layer may be made of one or more of natural rubber, synthetic rubber and thermoplastic elastomer.
For convenience of description, the surface of the hard core layer in contact with the elastic surface layer is hereinafter referred to as surface a, and the surface of the elastic surface layer in contact with the hard core layer is hereinafter referred to as surface B. The surface A is provided with a plurality of unit pieces, and the surface B is provided with a plurality of corresponding pieces.
In the above technical solution of the present invention, the metal section is a section, such as an aluminum alloy section, which is manufactured by a metal processing process and is suitable for a hard core layer of a composite floor, and the upper surface and the side surface of the metal section are in direct contact with the elastic surface layer, so that the metal section forms the surface a and has all the characteristics of the surface a.
In the technical scheme of the invention, the wood-plastic hot extrusion solid plate is a solid plate prepared by uniformly mixing the resin raw material, the plant fiber powder and the processing aid and then performing a conventional hot extrusion process, wherein the upper surface and the side surface of the plate also form the surface A and have all the characteristics of the surface A. In this sheet, the plastic commonly used is a polyolefin, more commonly polyethylene and polypropylene.
In the technical scheme of the invention, the wood-plastic hot-extruded hollow board and the wood-plastic hot-extruded solid board adopt the same raw materials, and only different processing dies are adopted. Because the die has the core rod protruding out of the die orifice, the plate forms a hollow structure at the corresponding position of the core rod. Likewise, the upper and side surfaces of the wood-plastic hot-extruded hollow panel constitute the surface a and have all the characteristics of the surface a described above.
In the technical scheme of the invention, the hard foamed self-skinning plate is a hard plate prepared by a foaming extrusion process from raw materials containing resin and a foaming agent, and the plate is provided with a self-skinning layer, wherein the thickness of the self-skinning layer is usually 0.1-1.0 mm. The inventor considers that the mechanical property of the hard PU foaming plate is lower, and the cost is higher; therefore, in the invention, the hard foamed self-skinning plate is particularly a hard PVC foamed self-skinning plate prepared from PVC resin. Because the PVC and the elastomer material have different properties and poor compatibility, the composite board cannot be produced according to the prior process of the PU board, and the problem that the elastomer surface layer and the PVC foaming core layer are not firmly combined can occur in the composite floor produced by a mould pressing method or a co-extrusion method. In view of the above, the present invention provides a matching structure between the hard core layer and the elastic surface layer; through the mutual embedding relation of the matching structures, the elastic surface layer is firmly combined with the hard core layer serving as the base material, so that the cracking between the core surface layers is avoided.
In the technical scheme of the invention, the hard foamed co-extruded clad plate is realized by co-extruding and cladding a hard plastic layer on the basis of the hard foamed self-skinned plate; the thickness of the self-skinning layer is 0.1-1.0 mm, and the mechanical properties need to be improved.
In the technical scheme of the invention, the hard foamed co-extrusion coated reinforced plate is a reinforced plate which is better in mechanical property than the hard foamed co-extrusion coated plate and is realized by additionally arranging a reinforcing layer between the co-extrusion coating layer and the hard foamed core layer of the plate on the basis of the hard foamed co-extrusion coated plate. The reinforcing layer is formed by impregnating glass fiber mesh cloth with resin and then curing; in view of processing convenience, incomplete curing is preferred, and the degree of curing may be 92 to 98% or more, for example, the degree of curing may be sufficient to have flexibility during production.
As a preferable mode of the above technical solution, the fitting structure further includes a plurality of first connecting units and a plurality of second connecting units; the first connecting unit is formed by the surface of the hard core layer, which is in contact with the elastic surface layer, and is arranged between two adjacent unit pieces; the second connecting unit is formed by the surface of the elastic surface layer, which is in contact with the hard core layer, and is arranged between two adjacent corresponding pieces; the first connecting unit and the second connecting unit are arranged in a matching mode.
Preferably, when the unit piece has a convex cross section, the convex fitting part having a groove cross section has a necking structure;
when the section of the unit piece is in the shape of a groove, the unit piece with the section in the shape of the groove has a necking structure.
In the above technical solution of the present invention, the necking structure means that an element having a horizontal surface has a concave portion, and an inner space of the concave portion is wide and a connection portion between the concave portion and the horizontal surface is narrow, so that a contraction structure is formed at the connection portion, so that after a second element having a corresponding structure is fitted with the second element, the second element is difficult to be released from the concave portion having the necking structure, thereby greatly improving a bonding force between the element and the second element.
Preferably, as for the above technical solution, the surface of the hard core layer contacting the elastic surface layer and the surface of the elastic surface layer contacting the hard core layer are provided with the unit piece and the corresponding piece at the transition connection between the horizontal direction and the vertical direction of the floor.
Preferably, the first connecting means and the second connecting means have a surface having a plane or a surface having a saw-toothed cross section. The surfaces of the first connecting unit and the second connecting unit are in a universal arrangement, and when the cross sections of the surfaces of the first connecting unit and the second connecting unit are in a sawtooth-shaped surface, the contact area of the surface A and the surface B can be obviously improved, and the resistance force between the elastic surface layer and the hard core layer generated when the elastic surface layer and the hard core layer are subjected to horizontal force can also be obviously improved, so that the binding force and the strain resistance force between the elastic surface layer and the hard core layer are improved.
Preferably, in the above aspect, the hard foamed self-skinning sheet material includes a hard foamed core made of a first foamed raw material containing a first resin, and a skin layer covering the hard foamed core and also made of the first foamed raw material.
Preferably, the hard foamed co-extruded clad plate is composed of a hard foamed core, a skinning layer cladding the hard foamed core and a co-extruded shell cladding the skinning layer; the rigid foam core and the skinning layer are formed from a first raw material comprising a first resin and a foaming agent, and the co-extruded shell is formed from a second raw material comprising a second resin and no foaming agent. The second resin and the first resin may be the same or different.
In the technical scheme of the invention, the hard foamed co-extruded cladding reinforced plate consists of a hard foamed core, a glass fiber reinforced layer and a co-extruded shell, wherein the glass fiber reinforced layer is arranged between the hard foamed core and the co-extruded shell; the hard foaming core and the skinning layer are formed by a first raw material containing a first resin and a foaming agent, and the co-extrusion shell is formed by a second raw material containing a second resin and no foaming agent; the glass fiber reinforced layer is formed by impregnating glass fiber mesh cloth with resin and then curing. The second resin and the first resin may be the same or different.
In the above technical solution of the present invention, the foaming agent comprises a chemical foaming agent, for example, the chemical foaming agent is added to the resin raw material in the form of a material; also, a physical blowing agent is included, such as a supercritical carbon dioxide fluid which is not added to the raw material but introduced through another inlet of the extruder and then mixed with the resin raw material inside the extruder.
According to the technical scheme, the mechanical strength of the hard core layer is improved by arranging the glass fiber reinforced layer in the hard core layer, so that the mechanical property of the whole plate is finally improved, and particularly the bending modulus of the whole plate is improved; so that the whole plate still shows good bending resistance at larger span; this can significantly reduce the amount of keel used, and provide great convenience for installation, transportation, and cost control, among other things.
Another object of the present invention is to provide a method for manufacturing the above double-layered composite flooring.
A production method of a double-layer composite floor comprises the following steps:
a. providing a casting mould, spraying a release agent into the casting mould, drying, pouring a liquid raw material for forming an elastic surface layer into the casting mould, and forming an elastic surface layer precursor with the thickness of a; the elastic surface layer precursor is an uncured liquid with fluidity;
b. placing a hard core layer having the unit pieces on the upper surface and the side surface into the casting mold;
c. applying a pressure to the hard core layer to make the hard core layer descend in the casting mould, so that the elastic surface layer precursor ascends along the gap between the inner side wall of the casting mould and the peripheral contour of the hard core layer and at least overflows the unit elements on the side surface of the hard core layer, and the thickness of the elastic surface layer precursor is reduced from a to b;
d. and c, maintaining the pressure applied in the step c, and curing the elastic surface layer precursor in the casting mould to obtain the double-layer composite floor.
In the technical scheme of the invention, the hard core layer is prefabricated and is manufactured into the plate by a mould pressing method. Compared with other methods, the mould pressing method has the advantages that the patterns or patterns of the mould can be clearly rubbed, so that the appearance simulation degree of the plate reaches an extremely high level, and the grade of the plate is obviously improved. The invention centrally puts the hard core layer with the unit element on at least the upper surface and the side surface into a casting mould containing an elastic surface layer precursor with the thickness of a, then presses to ensure that the elastic surface layer and the unit element form a fit structure, and coats the hard core layer to finally form the double-layer composite floor with the elastomer surface layer coating the hard core layer.
In the above technical solution of the present invention, the fact that the thickness of the elastic skin layer precursor in step c is changed to b means that the original thickness of the elastic skin layer precursor is reduced from the original thickness a to b because the elastic skin layer precursor is coated with the hard core layer.
Preferably, in the above-described aspect, the circumferential gap between the inner wall of the mold and the hard core layer is equal in width.
Preferably, in the above aspect, the mold is a wood grain mold.
Preferably, the hard core layer is a hard foamed co-extruded coating reinforced plate; the equipment for preparing the hard foamed co-extruded cladding reinforced plate comprises a main extruder, an auxiliary extruder, a co-extrusion die and a shaping die;
the co-extrusion die is formed by butting a plurality of die plates including a die feeding plate, a flow passage forming plate and a die discharging plate; the co-extrusion mold is provided with a main runner, a reinforcing material channel and a co-extrusion runner, and the main runner, the reinforcing material channel and the co-extrusion runner are independent in the mold; the reinforcing material channel comprises a first channel and a second channel which are distributed on two sides of the main flow channel, and a first discharge port and a second discharge port which are positioned on two sides of a discharge port of the main flow channel are formed on the mold discharge plate by the first channel and the second channel; the co-extrusion flow channel forms a surface layer discharge port on the mold discharge plate, the surface layer discharge port is in a rectangular ring structure and is sleeved around the main flow channel discharge port, and the first discharge port and the second discharge port are arranged between the main flow channel discharge port and the surface layer discharge port;
the surface layer discharge hole is provided with a structure corresponding to the unit element shape;
the reinforcing material channel comprises an input section and an output section, and the input section is connected with the output section; the included angle between the input section and the main runner gradually decreases along the material feeding direction until the included angle is zero; the reinforcing material feed inlet of the input section is arranged on the flow channel forming plate;
the co-extrusion flow channel comprises a feeding section, a casting section and a forming section which are communicated with each other, wherein the main body part of the feeding section is separately arranged on a second flow channel forming plate of the co-extrusion mould, the main body part of the casting section is arranged on a first flow channel forming plate of the mould, and the forming section is arranged on a discharging plate of the mould; the feeding section forms two branch channels on the second flow channel forming plate, and the flow casting section is two communicated inclined-plane-shaped channels formed on the first flow channel forming plate; the branch channel is butted with the inclined plane-shaped channel, and the inclined plane-shaped channel is butted with the molding section; the inner end surface of the mold discharging plate is in butt joint with the outer end surface of the first flow channel forming plate, and the inner end surface of the first flow channel forming plate is in butt joint with the outer end surface of the second flow channel forming plate; the rectangular annular structure of the cross section of the forming section gradually shrinks along the size of the discharging direction, and the surface layer discharging hole is formed on the discharging plate of the die;
the method for preparing the hard foamed co-extruded coating reinforced plate comprises the following steps:
fully mixing a first raw material containing a first resin and a foaming agent, inputting the mixture into a main extruder, extruding the first raw material into a main runner of a mold by the main extruder, and extruding the first raw material from the main runner to form a pressure maintaining core body;
simultaneously, inputting two glass fiber reinforced layers from a first channel and a second channel respectively;
meanwhile, a second raw material which contains second resin and does not contain a foaming agent is fully mixed and then fed into a co-extrusion flow channel of a co-extrusion die through an auxiliary extruder, and is extruded from a surface layer discharge port to obtain a co-extrusion shell with a frame-shaped section;
extruding the pressure maintaining core body, the glass fiber reinforced layer and the co-extrusion shell from respective flow channels to form a die blank; meanwhile, the mould blank is introduced into a setting mould, a pressure maintaining core body is foamed in a co-extrusion shell constrained by the inner wall of the setting mould in the setting mould, the co-extrusion shell is filled, and the mould blank is compounded and set in the setting mould to form the hard core layer; the mould blank comprises a pressure maintaining core body, a glass fiber reinforced layer and a co-extrusion shell from inside to outside in sequence, and a preformed foaming space is arranged between the pressure maintaining core body and the co-extrusion shell.
In the technical scheme of the invention, the whole co-extrusion die is formed by butt joint and combination of a die feeding plate, a plurality of flow passage forming plates and a die discharging plate. The die feeding plate and the die discharging plate are respectively arranged at two ends of the die, and the plurality of runner forming plates are arranged between the die feeding plate and the die discharging plate. According to the using method of the co-extrusion die, the die plate at the end where the material enters is a die feeding plate, and the die plate at the end where the product is extruded is a die discharging plate. And sequencing the plurality of runner plates, namely taking the closest mould discharge plate as a first runner forming plate, taking the next closest mould discharge plate as a second runner forming plate, and so on. The inner end surface of the mold discharge plate refers to a surface of the mold discharge plate facing the first flow channel forming plate, the outer end surface of the first flow channel forming plate refers to a surface of the first flow channel forming plate facing the mold discharge plate, the inner end surface of the first flow channel forming plate refers to a surface of the first flow channel forming plate facing the second flow channel forming plate, and the outer end surface of the second flow channel forming plate refers to a surface of the second flow channel forming plate facing the first flow channel forming plate.
The technical scheme of the invention provides a production method for arranging a glass fiber reinforced layer in a hard core layer. This is difficult for the person skilled in the art, since it is generally understood that the fusion of the glass fiber reinforced layer with the foam core requires the passage of the reinforcing material in communication with the primary flow channel, so that the glass fiber reinforced layer is fused into the foam layer. The problem that can do this is that, the inside of the main flow channel has great pressure intensity, once the reinforcing material channel is communicated with the main flow channel, the pressure intensity will be reversely released along the reinforcing material channel, the material in the main flow channel will be extruded into the reinforcing material channel naturally, and even further foaming will be carried out, so as to block the reinforcing material channel, so that the glass fiber reinforced layer is difficult to be continuously input, and the production is forced to be interrupted; typically, the mold must be disassembled to clear the channels of reinforcement material in a short production cycle. In addition, the hard core layer produced by the method is difficult to control in quality due to the fact that pressure is relieved in advance and partial area is foamed in advance.
In the technical scheme of the invention, the problems are solved by changing the production method and modifying the mould. Mainly expressed in the following aspects: on the mold, 1, a main runner is designed for pressure maintaining in the whole mold; 2. a co-extrusion flow channel is additionally arranged; 3. the reinforcing material channel and the co-extrusion flow channel are independent from the main flow channel and are converged at the port of the discharge plate of the mold; 4. a shaping mold is arranged at the outlet of the mold; in the method, 1, the concept that the composite board is formed from the outlet of a die in the past is abandoned, 2, a co-extrusion shell is introduced, so that when materials are combined at the outlet of the die, although the compounding is not realized, the automatic assembly required by the compounding is realized, then the materials enter a shaping die for compounding, the compounding of the board is realized at the front half part of the shaping die, and the shaping of the board is realized at the rear half part of the shaping die.
In the above technical solution of the present invention, the first resin is PVC resin. The second resin is selected from one or more of PVC, ASA, PE, PC, PP, ABS, etc.
Preferably, the sufficient mixing is that the first raw material is mixed in a high-speed mixer at the mixing temperature of 100-130 ℃ for 10-15 minutes, and then transferred to a cold mixer to be cooled to below 40 ℃.
In conclusion, the invention has the following beneficial effects:
1. according to the invention, the matching structure is arranged between the elastic surface layer and the hard foaming core layer, so that the elastic surface layer is firmly coated on the hard foaming core layer, and the elastic foaming core layer has the advantages of both the hard foaming core layer and the elastic surface layer, and has high compressive strength and good surface contact;
2. according to the invention, the glass fiber reinforced layer is arranged in the hard foam core layer, so that the compressive strength of the composite floor is further improved, the flexural modulus of the composite floor is obviously improved, the span can be increased when the floor is laid, the using amount of the keel is reduced, the laying cost is reduced, and the laying efficiency is improved; more importantly, the invention has better mechanical property at high temperature, and can still keep the bending strength above 20MPa at 80 ℃;
3. the invention provides a method for compounding a hard foaming core body and an elastic surface layer precursor, and the hard foaming core body can be better coated by the elastic surface layer precursor based on the method; after curing, the rigid foam core forms a rigid core layer of the composite floor, and the elastic surface layer precursor forms an elastic surface layer; and the composite floor has the advantage of high integrity;
4. the invention provides a production method of a hard foamed core body, in particular to a production method of a hard foamed core body additionally provided with a glass fiber reinforced layer, which forms another technical core of the invention; the hard foaming core prepared by the method can endow the composite floor with higher compressive strength, higher bending failure load and higher bending elastic modulus;
5. according to the invention, a certain amount of wear-resistant additive is added into the raw material of the elastic surface layer, so that the elastic surface layer has better surface wear resistance on the premise of slightly improving the surface hardness compared with the prior art.
Drawings
FIG. 1 is a schematic structural view of the present invention;
FIG. 2 is a schematic view of the mold construction of the present invention;
FIG. 3 is a schematic view of the outer end face of the first flow channel forming plate of the present invention;
in the figure, 1-elastic surface layer, 2-hard core layer;
201-co-extrusion shell, 202-glass fiber reinforced layer, 203-hard foaming core;
10-a main runner, 20-a reinforcing material channel and 30-a co-extrusion runner;
11-a main runner discharge port, 21-a first channel, 22-a second channel;
211-a first discharge port, 221-a second discharge port;
31-surface layer discharge hole;
201-input section, 202-output section;
301-feeding section, 302-casting section, 303-forming section;
3011-branch channel, 3021-ramp-like channel.
Detailed Description
The invention is further explained below with reference to the drawings.
This detailed description is to be construed as illustrative only and is not limiting, since any changes made by those skilled in the art after reading the present specification will be protected by the patent laws within the scope of the appended claims.
Example one
As shown in fig. 1, the double-layer composite floor comprises a hard core layer 2 and an elastic surface layer 1 made of PU material, wherein the hard core layer 2 is wrapped and covered on the upper surface and the side surface of the floor by the elastic surface layer 1.
A matching structure is arranged between the elastic surface layer 1 and the hard core layer 2, and the matching structure comprises a plurality of unit pieces formed on the surface A, a plurality of corresponding pieces formed on the surface B and a plurality of connecting units.
The surface a is the surface of the hard core layer 2 in contact with the elastic surface layer 1, and the surface B is the surface of the elastic surface layer 1 in contact with the hard core layer 2.
The connecting unit comprises a first connecting unit arranged between two adjacent unit pieces and a second connecting unit arranged between two adjacent corresponding pieces; the unit pieces are strip-shaped structures with groove-shaped sections and are arranged along the length direction of the floor; the corresponding part is a concave matching part which is embedded in the groove and has a convex section; the first connecting unit and the second connecting unit are arranged in a matching mode. The unit piece with the groove-shaped section has a necking structure.
In this embodiment, the hard core layer 2 is a hard foamed co-extruded clad reinforced plate. The hard foamed co-extruded cladding reinforced plate is composed of a hard foamed core 203, a glass fiber reinforced layer 202 and a co-extruded shell 201, wherein the glass fiber reinforced layer 202 is arranged between the hard foamed core 203 and the co-extruded shell 201; the hard foaming core 203 and the skinning layer thereof are formed by a first raw material containing a first resin and a foaming agent, and the co-extrusion shell 201 is formed by a second raw material containing a second resin and no foaming agent; the glass fiber reinforced layer is formed by impregnating glass fiber mesh cloth with resin and then curing. The thickness of the co-extruded shell is about 2 mm.
In this embodiment, the first resin is a PVC resin, and the foaming agent is an AC foaming agent. The second resin is also a PVC resin.
The production method of the double-layer composite floor comprises the following steps:
a. providing a casting mold, spraying 5g of magnesium stearate as a release agent and 50g of coating paint containing nano aluminum oxide into the casting mold in sequence, drying, mixing 2200g of polyether polyol, 15g of talcum powder, 600g of isocyanate and 4g of curing agent for 5 minutes, and pouring into the mold, wherein an elastic surface layer precursor with the thickness of about 2cm is formed in the casting mold with the depth of about 3 cm; the elastic skin precursor is liquid;
b. placing the hard core layer 2 with grooves on the upper surface and the side surface into the casting mold;
c. after the hard core layer 2 is laid flat, applying pressure to the hard core layer to enable the hard core layer to descend in the casting mould, so that the elastic surface layer precursor rises along the gap between the inner side wall of the casting mould and the peripheral outline of the hard core layer and at least overflows the groove on the side surface of the hard core layer, and the thickness of the elastic surface layer precursor is reduced from 2cm to about 0.5 cm;
d. and c, maintaining the pressure applied in the step c, and keeping the pressure for 20-25 minutes to cure the elastic surface layer precursor in the casting mould to obtain the double-layer composite floor.
In this embodiment, the hard core layer is a hard foamed co-extruded clad reinforced plate.
The equipment for preparing the hard foamed co-extruded cladding reinforced plate comprises a main extruder, an auxiliary extruder, a co-extrusion die and a shaping die;
as shown in fig. 2-3, the co-extrusion die is formed by butting a plurality of die plates including a die feed plate, a runner forming plate, and a die discharge plate.
The co-extrusion mold is provided with a main runner 10, a reinforcing material channel 20 and a co-extrusion runner 30, wherein the main runner 10, the reinforcing material channel 20 and the co-extrusion runner 30 are independent in the mold; the reinforcing material channel 20 comprises a first channel 21 and a second channel 22 distributed on two sides of the main runner 10, and the first channel 21 and the second channel 22 form a first discharge hole 211 and a second discharge hole 221 on two sides of a discharge hole 11 of the main runner on a mold discharge plate; the co-extrusion runner 30 forms a surface layer discharge port 31 on the mold discharge plate, the surface layer discharge port 31 is of a rectangular ring structure and is sleeved around the main runner discharge port 11, and the first discharge port 211 and the second discharge port 221 are arranged between the main runner discharge port 11 and the surface layer discharge port 31.
The surface layer discharge hole 31 is provided with a structure corresponding to the shape of the unit element.
The reinforcing material channel 20 comprises an input section 201 and an output section 202, wherein the input section 201 is connected with the output section 202; the included angle between the input section 201 and the main runner 10 gradually decreases along the material feeding direction until the included angle is zero; the reinforcing material feed port of the input section 201 is provided on the flow channel forming plate.
The co-extrusion runner 30 comprises a feeding section 301, a casting section 302 and a forming section 303 which are communicated with each other, wherein the main body part of the feeding section 301 is separately arranged on a second runner forming plate of the co-extrusion die, the main body part of the casting section 302 is arranged on a first runner forming plate of the die, and the forming section 303 is arranged on a discharge plate of the die; the feeding section 301 forms two branch channels 3011 on the second flow channel forming plate, and the casting section 302 is two mutually communicated inclined-plane-shaped channels 3021 formed on the first flow channel forming plate; the branch channel 3011 is butted with the inclined-plane-shaped channel 3021, and the inclined-plane-shaped channel 3021 is butted with the molding section 303; the inner end surface of the mold discharging plate is in butt joint with the outer end surface of the first flow channel forming plate, and the inner end surface of the first flow channel forming plate is in butt joint with the outer end surface of the second flow channel forming plate; the rectangular ring structure of the cross section of the molding section 303 gradually shrinks along the size of the discharging direction, and the surface layer discharging port 31 is formed on the outer end face of the discharging plate of the mold.
The whole co-extrusion die is formed by butt joint and combination of a die feeding plate, a plurality of flow passage forming plates and a die discharging plate. The die feeding plate and the die discharging plate are respectively arranged at two ends of the die, and the plurality of runner forming plates are arranged between the die feeding plate and the die discharging plate. According to the using method of the co-extrusion die, the die plate at the end where the material enters is a die feeding plate, and the die plate at the end where the product is extruded is a die discharging plate. And sequencing the plurality of runner plates, namely taking the closest mould discharge plate as a first runner forming plate, taking the next closest mould discharge plate as a second runner forming plate, and so on. The inner end surface of the mold discharge plate refers to a surface of the mold discharge plate facing the first flow channel forming plate, the outer end surface of the first flow channel forming plate refers to a surface of the first flow channel forming plate facing the mold discharge plate, the inner end surface of the first flow channel forming plate refers to a surface of the first flow channel forming plate facing the second flow channel forming plate, and the outer end surface of the second flow channel forming plate refers to a surface of the second flow channel forming plate facing the first flow channel forming plate.
The preparation method of the hard core layer 2 is as follows:
fully mixing a first raw material containing a first resin and a foaming agent (100 kg of PVC resin, 50kg of calcium carbonate, 0.5kg of stearic acid, 0.5kg of magnesium stearate, 5kg of calcium-zinc stabilizer, 1kg of AC foaming agent and 0.5kg of zinc oxide, mixing for 15 minutes in a high-speed mixer, mixing the mixture at the temperature of 120 ℃, then putting the mixture into a cold mixer to cool the mixture to 30 ℃), inputting the mixture into a main extruder, extruding the first raw material into a main runner 10 of a mold by the main extruder, and extruding the first raw material from the main runner 10 to form a pressure-maintaining core body;
meanwhile, two fiberglass reinforced layers are respectively input from the first channel 21 and the second channel 22;
meanwhile, fully mixing second raw materials (100 kg of PVC resin, 20kg of glass hollow microspheres, 50kg of calcium carbonate and 2.0kg of magnesium stearate) which contain second resin and do not contain a foaming agent, feeding the mixture from a co-extrusion flow channel 30 of a co-extrusion die through an auxiliary extruder, and extruding the mixture from a surface layer discharge port 31 to obtain a co-extrusion shell with a frame-shaped section;
extruding the pressure maintaining core body, the glass fiber reinforced layer and the co-extrusion shell from respective flow channels to form a die blank; and meanwhile, the die blank is introduced into a setting die, the pressure maintaining core body is foamed in a co-extrusion shell constrained by the inner wall of the setting die in the setting die, the co-extrusion shell is filled, and the die blank is compounded and set in the setting die to form the hard core layer. The mould blank comprises a pressure maintaining core body, a glass fiber reinforced layer and a co-extrusion shell from inside to outside in sequence, and a preformed foaming space is arranged between the pressure maintaining core body and the co-extrusion shell.
The process temperatures, speeds, pressures are shown in the following table:
Figure DEST_PATH_IMAGE002
example two
The difference from the first embodiment is that the hard core layer comprises a PVC hard foam core, a PVC skinning layer covering the PVC hard foam core, and a co-extruded shell covering the PVC skinning layer. Namely, the glass fiber reinforced layer is not included, and the thickness of the PVC skinning layer is about 0.5 mm; the thickness of the co-extruded shell is about 2 mm.
The preparation method of the hard core layer comprises the following steps:
fully mixing PVC foaming materials (100 kg of PVC resin, 50kg of calcium carbonate, 0.5kg of stearic acid, 0.5kg of magnesium stearate, 5kg of calcium-zinc stabilizer, 1kg of AC foaming agent and 0.5kg of zinc oxide, mixing for 15 minutes in a high-speed mixer, cooling to 30 ℃ in a cold mixer, and extruding from a die orifice of a die by a main extruder;
meanwhile, fully mixing second raw materials (100 kg of PVC resin, 20kg of glass cenospheres, 50kg of calcium carbonate and 2.0kg of magnesium stearate) which contain second resin and do not contain a foaming agent, feeding the mixture from a co-extrusion flow channel of a co-extrusion die through an auxiliary extruder, and extruding the mixture from a surface layer discharge port to obtain a co-extrusion shell with a frame-shaped section;
extruding the pressure maintaining core body and the co-extrusion shell from respective flow channels to form a die blank; and meanwhile, the die blank is introduced into a setting die, the pressure maintaining core body is foamed in a co-extrusion shell constrained by the inner wall of the setting die in the setting die, the co-extrusion shell is filled, and the die blank is compounded and set in the setting die to form the hard core layer. And a preformed foaming space is arranged between the pressure maintaining core body and the co-extrusion shell.
Compared with the first embodiment, the co-extrusion die in the embodiment lacks the reinforcing material channel part, and the rest is the same.
EXAMPLE III
The difference from the first embodiment is that the hard core layer is a preformed aluminum alloy profile. The preparation method is the same as the first embodiment.
Example four
The difference from the first embodiment is that the hard core layer is a wood-plastic hot-extruded solid plate; the wood-plastic hot extrusion solid plate is a solid plate prepared by uniformly mixing a resin raw material, plant fiber powder and a processing aid and then performing a conventional hot extrusion process, wherein the upper surface and the side surface of the plate also form the surface A and have all the characteristics of the surface A. In the plate, the common plastic is polyolefin, and in this embodiment, the resin is a mixture of polyethylene and polypropylene, wherein 38kg of polyethylene, 2kg of polypropylene and 100kg of plant fiber powder are used.
The preparation method is the same as the first embodiment.
EXAMPLE five
The difference from the first embodiment is that the hard core layer is a wood-plastic hot-extruded hollow plate; the wood-plastic hot-extruded hollow board is consistent with the wood-plastic hot-extruded solid board in raw material, and only the processed mould is different. Because the die has the core rod protruding out of the die orifice, the plate forms a hollow structure at the corresponding position of the core rod. Likewise, the upper and side surfaces of the wood-plastic hot-extruded hollow panel constitute the surface a and have all the characteristics of the surface a described above.
The preparation method is the same as the first embodiment.
Comparative example 1
According to WO2018154287A1, a PU plate is prepared by the method disclosed by the low-heat-absorption flame-retardant polyurethane wood-like material.
The products of examples I and II and the product of comparative example I were tested in accordance with the relevant contents of GB/T245908-2009, GB/T24137-209, GB/T2411-2008 and GB/T18102-2007, and the bending breaking load, bending strength, surface hardness and surface wear resistance were measured to obtain the results shown in the following tables.
Figure DEST_PATH_IMAGE004

Claims (10)

1. A double-layer composite floor is characterized in that: the floor board comprises a hard core layer (2) with the Shore hardness of more than 80HD and an elastic surface layer (1) with the Shore hardness of less than 40HD, wherein the elastic surface layer (1) covers the hard core layer (2) on the upper surface and at least partial side surface of the floor board; a matching structure is arranged between the elastic surface layer (1) and the hard core layer (2), and comprises a plurality of single elements formed on the surface of the hard core layer and a plurality of corresponding elements formed on the surface of the elastic surface layer; the unit pieces are strip-shaped structures which are arranged along the length direction of the floor and have convex or groove-shaped sections;
when the section of the unit piece is in a convex shape, the corresponding piece is a convex matching part which wraps the convex and has a groove shape in section;
when the section of the unit piece is in a groove shape, the corresponding piece is a groove matching part which is embedded in the groove and has a convex section;
the material of the elastic surface layer is selected from one or more of natural rubber, synthetic rubber or thermoplastic elastomer;
the hard core layer is selected from one of a metal section, a wood-plastic hot extrusion solid plate, a wood-plastic hot extrusion hollow plate, a hard foaming self-skinning plate, a hard foaming co-extrusion coating plate and a hard foaming co-extrusion coating reinforced plate.
2. The double-layered composite flooring according to claim 1, wherein: the mating structure further comprises a plurality of first connection units and a plurality of second connection units; the first connecting unit is formed by the surface of the hard core layer, which is in contact with the elastic surface layer, and is arranged between two adjacent unit pieces; the second connecting unit is formed by the surface of the elastic surface layer, which is in contact with the hard core layer, and is arranged between two adjacent corresponding pieces; the first connecting unit and the second connecting unit are arranged in a matching mode.
3. The double-layered composite flooring according to claim 1, wherein: when the section of the unit piece is in a convex shape, the convex matching part with the section in a groove shape has a necking structure;
when the section of the unit piece is in the shape of a groove, the unit piece with the section in the shape of the groove has a necking structure.
4. The double-layered composite flooring according to claim 1, wherein: the surface of the hard core layer, which is contacted with the elastic surface layer, and the surface of the elastic surface layer, which is contacted with the hard core layer, are provided with the unit piece and the corresponding piece at the transition connection position of the horizontal direction and the vertical direction of the floor.
5. The double-layered composite flooring according to claim 2, wherein: the surfaces of the first connecting unit and the second connecting unit are planes or surfaces with saw-toothed sections.
6. The double-layered composite flooring according to claim 1, wherein: the hard foamed self-skinning plate is composed of a hard foamed core formed by a first foaming raw material containing a first resin and a skinning layer which covers the hard foamed core and is also formed by the first foaming raw material.
7. The double-layered composite flooring according to claim 1, wherein: the hard foamed co-extruded clad plate consists of a hard foamed core, a skinning layer cladding the hard foamed core and a co-extruded shell cladding the skinning layer; the rigid foam core and the skinning layer are formed from a first raw material comprising a first resin and a foaming agent, and the co-extruded shell is formed from a second raw material comprising a second resin and no foaming agent.
8. The double-layered composite flooring according to claim 1, wherein: the hard foamed co-extruded cladding reinforced plate consists of a hard foamed core, a glass fiber reinforced layer and a co-extruded shell, wherein the glass fiber reinforced layer is arranged between the hard foamed core and the co-extruded shell; the hard foaming core and the skinning layer are formed by a first raw material containing a first resin and a foaming agent, and the co-extrusion shell is formed by a second raw material containing a second resin and no foaming agent; the glass fiber reinforced layer is formed by impregnating glass fiber mesh cloth with resin and then curing.
9. The method for manufacturing a double-layered composite flooring according to any one of claims 1 to 8, comprising the steps of:
a. providing a casting mould, spraying a release agent into the casting mould, drying, pouring a liquid raw material for forming the elastic surface layer (1) into the casting mould, and forming an elastic surface layer precursor with the thickness of a; the elastic surface layer precursor is an uncured liquid with fluidity;
b. placing a hard core layer (2) having the unit pieces on the upper surface and the side surface into the mold;
c. applying a pressure to the hard core layer to make the hard core layer descend in the casting mould, so that the elastic surface layer precursor ascends along the gap between the inner side wall of the casting mould and the peripheral contour of the hard core layer and at least overflows the unit elements on the side surface of the hard core layer, and the thickness of the elastic surface layer precursor is reduced from a to b;
d. and c, maintaining the pressure applied in the step c, and curing the elastic surface layer precursor in the casting mould to obtain the double-layer composite floor.
10. The method for producing the double-layer composite floor as claimed in claim 1, wherein the hard core layer (2) is a hard foamed co-extruded clad reinforced plate;
the equipment for preparing the hard foamed co-extruded cladding reinforced plate comprises a main extruder, an auxiliary extruder, a co-extrusion die and a shaping die;
the co-extrusion die is formed by butting a plurality of die plates including a die feeding plate, a flow passage forming plate and a die discharging plate; the co-extrusion mold is provided with a main runner (10), a reinforcing material channel (20) and a co-extrusion runner (30), wherein the main runner (10), the reinforcing material channel (20) and the co-extrusion runner (30) are independent from each other in the mold; the reinforcing material channel (20) comprises a first channel (21) and a second channel (22) which are distributed on two sides of the main flow channel (10), and a first discharge hole (211) and a second discharge hole (221) which are positioned on two sides of a discharge hole (11) of the main flow channel are formed in the mold discharge plate by the first channel (21) and the second channel (22); the co-extrusion runner (30) forms a surface layer discharge port (31) on a die discharge plate, the surface layer discharge port (31) is of a rectangular ring structure and is sleeved around the main runner discharge port (11), and the first discharge port (211) and the second discharge port (221) are arranged between the main runner discharge port (11) and the surface layer discharge port (31);
the surface layer discharge hole (31) is provided with a structure corresponding to the unit element shape;
the reinforcing material channel (20) comprises an input section (201) and an output section (202), wherein the input section (201) is connected with the output section (202); the included angle between the input section (201) and the main runner (10) gradually decreases along the material feeding direction until the included angle is zero; the reinforcing material feed inlet of the input section (201) is arranged on the flow channel forming plate;
the co-extrusion runner (30) comprises a feeding section (301), a casting section (302) and a forming section (303) which are communicated with each other, wherein the main body part of the feeding section (301) is separately arranged on a second runner forming plate of the co-extrusion die, the main body part of the casting section (302) is arranged on a first runner forming plate of the die, and the forming section (303) is arranged on a discharging plate of the die; the feeding section (301) forms two branch channels (3011) on the second flow channel forming plate, the casting section (302) is two communicated inclined-plane channels (3021) on the first flow channel forming plate; the branch channel (3011) is butted with the inclined-plane-shaped channel (3021), and the inclined-plane-shaped channel (3021) is butted with the molding section (303); the inner end surface of the mold discharging plate is in butt joint with the outer end surface of the first flow channel forming plate, and the inner end surface of the first flow channel forming plate is in butt joint with the outer end surface of the second flow channel forming plate; the rectangular annular structure of the cross section of the forming section (302) gradually shrinks along the size of the discharging direction, and the surface layer discharging hole (31) is formed on the discharging plate of the die;
the method for preparing the hard foamed co-extruded coating reinforced plate comprises the following steps:
fully mixing a first raw material containing a first resin and a foaming agent, inputting the mixture into a main extruder, extruding the first raw material into a main flow channel (10) of a mold by the main extruder, and extruding the first raw material from the main flow channel (10) to form a pressure maintaining core body;
simultaneously, inputting two glass fiber reinforced layers from a first channel (21) and a second channel (22) respectively;
meanwhile, a second raw material which contains second resin and does not contain a foaming agent is fed from a co-extrusion flow channel (30) of a co-extrusion die through an auxiliary extruder after being fully mixed, and is extruded from a surface layer discharge hole (31), so that a co-extrusion shell with a frame-shaped section is obtained;
extruding the pressure maintaining core body, the glass fiber reinforced layer and the co-extrusion shell from respective flow channels to form a die blank; meanwhile, the mould blank is introduced into a setting mould, a pressure maintaining core body is foamed in a co-extrusion shell body restrained by the inner wall of the setting mould in the setting mould, the co-extrusion shell body is filled, and meanwhile, the mould blank is compounded and set in the setting mould to form the hard core body; the mould blank comprises a pressure maintaining core body, a glass fiber reinforced layer and a co-extrusion shell from inside to outside in sequence, and a preformed foaming space is arranged between the pressure maintaining core body and the co-extrusion shell.
CN202110410427.9A 2021-04-16 2021-04-16 Double-layer composite floor and preparation method thereof Pending CN113043704A (en)

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AU2021102069A AU2021102069A4 (en) 2021-04-16 2021-04-20 Double-layer composite floor
DE202021102329.5U DE202021102329U1 (en) 2021-04-16 2021-04-29 Two-layer laminate floor

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