CN113513139A - 一种高分子实木复合地板及其制备方法 - Google Patents
一种高分子实木复合地板及其制备方法 Download PDFInfo
- Publication number
- CN113513139A CN113513139A CN202110946190.6A CN202110946190A CN113513139A CN 113513139 A CN113513139 A CN 113513139A CN 202110946190 A CN202110946190 A CN 202110946190A CN 113513139 A CN113513139 A CN 113513139A
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- Prior art keywords
- equal
- solid wood
- layer
- less
- wood composite
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Abstract
本发明涉及一种地板，特别涉及一种高分子实木复合地板。高分子实木复合地板，包括SPC石塑层，所述SPC石塑层下方设置有形成地板主体的实木单板层或胶合板层；所述高分子实木复合地板的理化性能指标为：色牢度≥6级；剥离强度平均值≥75(N/50mm)，耐污染≥5级，加热尺寸变化率≤0.25％，加热翘曲度≤2.0mm，含水率为6‑10％。高分子实木复合地板的制备工艺，包括：SPC石塑层制备；实木单板层或胶合板层制备；复合压贴：将SPC石塑层与实木单板层或胶合板层压贴；一次平衡处理；分切；二次平衡处理；开槽；UV层制备。本发明通过在SPC石塑层下复合压贴形成地板主体的实木单板层或胶合板层，然后分切前后分别进行平衡处理，可制得脚感好、不易变形开裂、尺寸变化率小。
Description
技术领域
本发明涉及一种地板，特别涉及一种高分子实木复合地板。
背景技术
传统的陶瓷地板、实木地板、复合地板存在脚感冰硬、易变形、甲醛超标等现象，已经不能满足人们的要求，迫切需要一种既柔软、不易变形又环保的室内地板。PVC地板的主要成分为聚氯乙烯材料，于其花色丰富，色彩多样而被广泛用于居家和商业的各方面。
SPC地板是一种新型地板，又称石塑地板，其基材由石粉与热塑高分子材料在搅拌均匀后再经高温挤压制成的复合板材，同时兼有木材与塑料的性能与特征，确保地板的强度与韧性。传统SPC石塑地板密度1900-2000kg/m3。由于SPC地板厚度在2-3mm，对装修时找平要求极高，而且存在脚感差、安装困难等问题。
发明内容
本发明的目的之一是克服上述困难，提供一种脚感好、容易安装的高分子实木复合地板。
本发明的目的之二是克服上述困难，提供一种脚感好、容易安装的高分子实木复合地板的制备方法。
本发明的上述第一技术目的是通过以下技术方案得以实现的：
一种高分子实木复合地板，包括SPC石塑层，所述SPC石塑层下方设置有形成地板主体的实木单板层或胶合板层；所述高分子实木复合地板的理化性能指标为：色牢度≥6级；剥离强度平均值≥75(N/50mm)，耐污染≥5级，加热尺寸变化率≤0.25％，加热翘曲度≤2.0mm，含水率为6-10％。
经过发明人进行多次实验，本发明的高分子实木复合地板在SPC石塑层下设置有形成地板主体的实木单板层或胶合板层，脚感好，安装方便。本发明利用SPC地板的防火性能、抗菌、防水性能和实木/胶合板的稳定性、木材脚感好性能，经过材料复合，解决石塑地板脚感差、安装要求高及安装困难的缺点。
作为优选，所述胶合板层为两层结构、五层结构、七层结构和九层结构。
作为优选，所述SPC层上方从上而下依次设置有UV漆层、耐磨片层和树脂膜层。
作为优选，所述高分子实木复合地板的理化性能指标为：弹性模量≥4000MPa，静曲强度≥30MPa，表面耐磨≤0.08g/100r，漆膜硬度≥2H，总挥发物限量≤40g/㎡，可溶性镉(Cd)≤20mg/㎡，可溶性铅(Pb)≤20mg/㎡，甲醛释放量≤0.050mg/m3，冷热翘曲度≤2.0mm，防霉性≤1级。
作为优选，所述高分子实木复合地板的开槽尺寸指标为：
直角度qmax≤0.1mm；边缘不直度smax≤0.15mm；
翘曲度：宽度方向凸翘度fw≤0.20％；宽度方向凹翘曲度fw≤0.15％；长度方向凸翘度fl≤0.5％，长度方向凹翘曲度fl≤0.25％。
作为优选，当所述SPC层下方的地板主体为胶合板层时，胶合板的性能指标为：含水率为10-12％，弹性模量≥4000MPa，静曲强度≥40MPa，甲醛释放量≤0.025mg/m3。
作为优选，所述SPC层的理化性能指标要求为：色牢度≥6级；剥离强度平均值≥75(N/50mm)，耐污染≥5级，防霉性≤1级，加热尺寸变化率≤0.25％，加热翘曲度≤2.0mm，冷热翘曲度≤2.0mm，可溶性镉(Cd)≤20mg/㎡，可溶性铅(Pb)≤20mg/㎡，甲醛释放量≤0.025mg/m3。
作为本发明的一种优选技术方案，所述复合板材包括底板、石塑PVC、耐磨片、树脂膜和UV耐磨漆膜，所述石塑PVC粘接于所述底板上，所述耐磨片粘接于所述石塑PVC上，所述树脂膜粘接于所述耐磨片上，所述UV耐磨漆膜粘接于所述树脂膜上。
作为优选，一种实木复合地板，包括复合板材、卡块和卡槽，所述复合板材的一侧与所述卡块一体成型，所述卡槽开设于所述复合板材上相对于所述卡块的一侧，所述卡块与所述卡槽相匹配；
其中，所述卡块上开设有直角卡槽，所述卡块靠近所述直角卡槽的位置一体成型有梯形凸块，所述卡块与所述复合板材的底部连接处开设有条形槽，所述直角卡槽与所述条形槽均为贯穿式；
其中，所述复合板材靠近所述卡槽的一侧固定连接有直角凸块，所述复合板材靠近所述卡槽的一侧开设有梯形槽，所述复合板材靠近所述卡槽的一侧一体成型有条形凸块。
多个实木复合地板之间可以相互嵌套固定，通过将其中一个实木复合地板上的卡块插入另外一个实木复合地板上的卡槽，实现多个本发明实木复合地板之间的连接固定，当两个本发明的实木复合地板连接后，直角凸块会插入直角卡槽内，梯形凸块会插入梯形槽内，条形凸块会插入条形槽内，三组销槽相互匹配相互作用，提高实木复合地板连接的稳定性，其中，梯形凸块与梯形槽相互作用，有效的防止实木复合地板之间纵向交错位移，直角凸块与直角卡槽配合，条形凸块与条形槽配合，可以有效的防止实木复合地板之间横向位移；同时，连接时，可以将卡块倾斜插入卡槽内，轻晃卡块，即可将卡块方便的完全匹配的贴合插入卡槽内，连接方便快速
作为本发明的一种优选技术方案，所述底板上开设有内槽，所述内槽内开设有两个对称设置的置物槽，所述底板上开设有边槽。
作为本发明的一种优选技术方案，所述石塑PVC上一体成型有两个对称设置的连板，所述石塑PVC的底部开设有十字槽，所述连板粘接于所述边槽内。
作为本发明的一种优选技术方案，所述直角凸块与所述直角卡槽相匹配，所述梯形凸块与所述梯形槽相匹配，所述条形槽与所述条形凸块相匹配。
作为本发明的一种优选技术方案，所述梯形凸块的左下角边角角度大于九十度小于一百五十度。
作为本发明的一种优选技术方案，所述底板为实木单板或多层板胶合板。
本发明的上述第二技术目的是通过以下技术方案得以实现的：
一种高分子实木复合地板的制备工艺，包括：
(1)SPC层制备；
(2)实木单板层或胶合板层制备；
(3)复合压贴：将SPC层与实木单板层或胶合板层压贴；
(4)一次平衡处理；
(5)分切；
(6)二次平衡处理；
(7)开槽；
(8)UV漆层制备。
本发明通过在SPC层下复合压贴形成地板主体的实木单板层或胶合板层，然后分切前后分别进行平衡处理，可制得脚感好、不易变形开裂、尺寸变化率在0.25％以下的高分子实木复合地板。
作为优选，SPC层制备包括以下步骤：
S1,原料配比：按重量份包括聚氯乙烯树脂粉80-90份、碳酸钙160-180份、钛酸钙10-30份、内润滑剂0.6-0.8份、聚乙烯蜡1.0-1.2份、氯化聚乙烯2-4份、丙烯酸酯0.8-1.5份、复合润滑剂0.6-0.9份、液体钡锌稳定剂2-3份；
S2,将上述原料投入高速搅拌机进行混料升温，再经低速搅拌降温，然后经挤出机挤出。
润滑剂可以分为内润滑和外润滑两种。外润滑剂的主要作用是改善聚合物熔体与加工设备的热金属表面的摩擦。它与聚合物相容性较差，容易从熔体往外迁移，所以能在塑料熔体与金属的交界面形成润滑的薄层。内润滑剂与聚合物有良好的相容性，它在聚合物内部起到降低聚合物分子间内聚力的作用，从而改善塑料熔体的内摩擦生热和熔体的流动性。由于外润滑剂容易从熔体往外迁移的特性，使得塑料熔体在成型后易于跟模具脱离，故也常常把外润滑剂叫做脱模剂。但内润滑剂和外润滑剂并不是绝对的。会根据熔体的性质发生转变。如常见的润滑剂聚乙烯蜡和硬脂酸；当用于聚乙烯树脂时，聚乙烯蜡相容性较好，留在树脂内部作内润滑剂；当用于聚氯乙烯树脂时，硬脂酸相容性较好，留在树脂内部作内润滑剂，聚乙烯蜡相容性较差，迁移出树脂外部做外润滑剂。
而复合润滑剂，通常是指多元醇脂类。如辛酸、癸酸、月桂酸、棕榈酸、油酸、硬脂酸、花生酸、巳二酸、癸二酸等，由它们通过酯化、醇解、酯交换组成的多元醇脂类或经过多次酯化组成和复合组成的高分子复合醇酯产品的润滑剂。在这类润滑剂中，多元醇酯类的产品都是多元醇的部分酯化，在酯类中尚有未反应的羟基存在。极性的羟基基团常赋予制品良好的抗静电作用。因此，这些润滑剂也是PVC加工中的抗静电剂。季戊四醇脂肪酸酯是一种含有单、双、叁、肆酯的混合物，在PVC加工中，有良好的内润滑作用。这类产品由于反应程度的不同，随着羟基数的增加，其内润滑作用就会向外润滑剂转移。
作为优选，所述步骤(3)复合压贴工艺参数包括；冷压温度10-45℃,压力：15±0.5MPa,时间：40-45分钟,其中无压力停放时间为控制在20分钟之内,压贴产品必须经过72小时存放进行后固化处理。
本发明复合压贴过程中必须严格控制温度、压力和时间；若冷压温度和压力过低，复合压贴使用的胶水容易在SPC层和胶合板层之间形成胶膜层而难以渗透入上下的SPC层和胶合板层，压贴效果差，胶合强度显著降低，复合板材容易松动；若冷压温度和压力过高，则会使复合板材含水率过低，影响高分子实木复合地板的脚感，降低稳定性；而且会影响胶水粘结性能，导致地板发生变形开裂和翘曲。
更优选地，所述复合压贴使用的胶水要求为无醛胶水或无水胶水。
更优选地，所述复合压贴使用的胶水为异氰酸酯或其它冷压胶。
作为优选，所述步骤(6)二次平衡处理包括将分切后的板材，按照“#”进行码放，要进行防潮防护，四周要使用缠绕膜缠绕起来，必须经过72小时以上平衡处理才能够进入开槽工序。
作为优选，所述胶合板层是由木段旋切成单板或由木方刨切成薄木，再用胶黏剂胶合而成的两层或两层以上的多层的单板材料，并使相邻层单板的纤维方向互相垂直胶合而成；所述单板材料为木质单板表面等离子体改性后的单板。
更优选地，所述胶黏剂为羟甲基化木质素和三聚氰胺-脲醛树脂共混技术制备而成，制备方法包括：采用球磨法在振荡频率为10-50Hz时处理40-80min，得到木质素粉末；再通过与甲醛溶液和固体碱物质进行加成反应形成羟甲基化木质素；将羟甲基化木质素按20-40wt％的比例与MUF树脂均匀混合，制得低甲醛的木质素-三聚氰胺脲醛树脂胶黏剂。
进一步优选地，所述胶黏剂为羟甲基化木质素和三聚氰胺-脲醛树脂共混技术制备而成，具体是采用球磨法在振荡频率为20Hz时处理60min，得到木质素粉末；再通过与甲醛溶液和固体碱物质进行加成反应形成羟甲基化木质素；将羟甲基化木质素按30％的比例与MUF树脂均匀混合，制得低甲醛的木质素-三聚氰胺脲醛树脂胶黏剂。
更优选地，所述木质单板表面等离子体改性工艺具体包括：采用常压低温介质阻挡放电等离子体技术，对木质单板进行改性处理，利用等离子体的刻蚀作用，改变单板表面微观结构。
本发明通过等离子体改性在单板表面上重构具有纳米结构的高活性表面层，利用等离子体的氧化、分解和接枝等作用在单板表面引入特定的极性官能团，从而促进胶粘剂与木材间的界面胶合，在不改变胶粘剂用量的前提下，利用低温等离子体改性木质单板制成复合材料的胶合强度提高15-50％。本发明在保证产品质量达到国家标准要求的前提下，胶黏剂用量可较常规用量减少10～25％，显著降低了生产成本，减少了产品游离甲醛释放。
采用常压低温介质阻挡放电等离子体(DBD)技术，对木质单板进行改性处理，利用等离子体的刻蚀作用，改变单板表面微观结构，促使胶粘剂在木材表面分布更加均匀，与木材的接触面积大幅度增加，同时，利用等离子体的氧化、分解和接枝等作用在单板表面引入特定的极性官能团，从而促进胶粘剂与木材间的界面胶合，使木质复合材料的品质大幅度提高。针对不同性能要求的木质复合材料，可通过调节常压低温等离子体处理工艺(包括放电时间、放电功率、电极个数、放电距离等)以及单板自身特性(如单板含水率等)，以及环保脲醛树脂胶黏剂施胶和胶合工艺(如施胶量、热压温度、热压时间等)，可使产品获得不同的胶合性能，形成了木质复合材料常压低温等离子体改性工业化生产技术。
综上所述，本发明具有以下有益效果：
1、经过发明人进行很多的实验，本发明的高分子实木复合地板在SPC层下设置有形成地板主体的实木单板层或胶合板层，脚感好，安装方便。本发明利用SPC地板的防火性能、抗菌、防水性能和实木/胶合板的稳定性、木材脚感性能，经过材料复合，解决石塑地板脚感差、安装要求高及安装困难的缺点；
2、本发明通过在SPC石塑层下复合压贴形成地板主体的实木单板层或胶合板层，然后分切前后分别进行平衡处理，可制得脚感好、不易变形开裂、尺寸变化率在0.2％以下的高分子实木复合地板。
附图说明
图1为本发明实木复合地板的立体图；
图2为本发明爆炸结构示意图；
图3为本发明石塑PVC的结构示意图；
图4为本发明复合板材的剖视图；
图5为本发明图1中A区结构放大示意图；
图6为本发明图1中B区结构放大示意图。
图中：1、复合板材；2、卡块；3、卡槽；11、底板；12、石塑PVC；13、耐磨片；14、树脂膜；15、UV耐磨漆膜；21、直角卡槽；22、梯形凸块；23、条形槽；31、直角凸块；32、梯形槽；33、条形凸块；121、连板；111、边槽；112、内槽；113、放置槽；122、十字槽。
具体实施方式
实施例1
1、高分子实木复合地板，包括SPC层，SPC层下方设置有形成地板主体的实木单板层或胶合板层；高分子实木复合地板的理化性能指标为：色牢度≥6级；剥离强度平均值≥75(N/50mm)，耐污染≥5级，加热尺寸变化率≤0.25％，加热翘曲度≤2.0mm，含水率为6-10％。
为了进一步提高复合地板的脚感、耐磨性和减小尺寸变化率，SPC层上方从上而下依次设置有UV漆层、耐磨片层和树脂膜层。
高分子实木复合地板的制备工艺，包括：
(1)SPC层制备；
(2)实木单板层或胶合板层制备；
(3)复合压贴：将SPC层与实木单板层或胶合板层压贴；
(4)一次平衡处理；
(5)分切；
(6)二次平衡处理；
(7)开槽；
(8)UV层制备。
SPC层制备包括以下步骤：
S1,原料配比：按重量份包括聚氯乙烯树脂粉80份、碳酸钙160份、钛酸钙10份、内润滑剂0.6份、聚乙烯蜡1.0份、氯化聚乙烯2份、丙烯酸酯0.8份、复合润滑剂0.6份、液体钡锌稳定剂3份；
S2,将上述原料投入高速搅拌机进行混料升温，再经低速搅拌降温，然后经挤出机挤出。
步骤(3)复合压贴工艺参数包括；冷压温度10℃,压力：15MPa,时间：40分钟,其中无压力停放时间为15分钟,压贴产品经过72小时存放进行后固化处理。
2、胶合板控制标准
备注：弹性模量和静曲强度；厚度≥6mm要求，＜6mm此项不检测要求。
3、对于各种备注工序说明：
3.1压贴各种要求：
3.1.1胶水的要求
对于使用的胶水要求：无醛胶水和无水胶水(异氰酸酯或其它冷压胶)
3.1.2对于压贴工艺技术要求：
经过数次的压贴实验及对于相应半成品性能检测，在下面工艺条件下认为最好：冷压温度(室内)：≥30℃和＜30℃，胶水要求的配方是不同，特别注意(室内温度低于10℃，严禁压贴)。压力：15±0.5MPa，时间：40-45分钟，其中无压力停放时间为控制在20分钟之内。
压贴产品必须经过72小时存放进行后固化处理，才是能够进入分切工序。
3.2对于分切的技术要求
3.2.1规格尺寸：
成品的要求的尺寸进行分切留够企口加工的余量
3.2.2外观质量要求：
3.3对于平衡要求：
分切后的小片，按照“#”进行码放，要进行防潮防护，四周要使用缠绕膜缠绕起来，必须进过72小时平衡处理才能够进入开槽工序；
3.4开槽技术要求：
3.4.1高分子实木复合地板开槽外观质量要求:
3.4.2高分子实木复合地板开槽尺寸质量要求
3.5、滚漆生产技术要求
3.5.1高分子实木复合地板外观质量要求:
3.5.2高分子实木复合地板尺寸质量要求:
3.5.3高分子实木复合地板板理化性能指标：
3.6包装要求
3.6.1产品加工完成，按产品类别、等级分别包装；
3.6.2包装盒中必须放入一份供消费者阅读的安装和使用说明书；
3.6.3塑封处理避免产品受磕碰、划伤和污损以及防止产品在运输、存储过程中干、湿度变化影响板面质量；
4、高分子实木复合地板地板的特点
既有实木复合特点、脚感好、安装简单、吸音隔声、温暖、保温性能好、又具有SPC地板耐磨、环保、无毒、无害、抗菌、阻燃性能、防水防潮、绝缘性能好、款式丰富、抗变形、耐污染、不褪色等特点。高分子实木复合地板改善SPC地板脚感差的问题。
实施例2
同实施例1，不同的是SPC层制备包括以下步骤：
S1,原料配比：按重量份包括聚氯乙烯树脂粉90份、碳酸钙180份、钛酸钙30份、内润滑剂0.8份、聚乙烯蜡1.2份、氯化聚乙烯4份、丙烯酸酯1.5份、复合润滑剂0.9份、液体钡锌稳定剂2份；
S2,将上述原料投入高速搅拌机进行混料升温，再经低速搅拌降温，然后经挤出机挤出。
步骤(3)复合压贴工艺参数包括；冷压温度45℃,压力：14.5MPa,时间：45分钟,其中无压力停放时间为控制在20分钟之内,压贴产品经过73小时存放进行后固化处理。
实施例3
同实施例1，不同的是SPC层制备包括以下步骤：
S1,原料配比：按重量份包括聚氯乙烯树脂粉85份、碳酸钙170份、钛酸钙20份、内润滑剂0.7份、聚乙烯蜡1.1份、氯化聚乙烯3份、丙烯酸酯1.2份、复合润滑剂0.8份、液体钡锌稳定剂2.3份；
S2,将上述原料投入高速搅拌机进行混料升温，再经低速搅拌降温，然后经挤出机挤出。
步骤(3)复合压贴工艺参数包括；冷压温度25℃,压力：15.5MPa,时间：42分钟,其中无压力停放时间为控制在20分钟之内,压贴产品经过75小时存放进行后固化处理。
实施例4
同实施例1，不同的是其中，胶合板层是由木段旋切成单板或由木方刨切成薄木，再用胶黏剂胶合而成的两层或两层以上的多层单板材料，并使相邻层单板的纤维方向互相垂直胶合而成；单板材料为木质单板表面等离子体改性后的单板。
其中，胶黏剂为羟甲基化木质素和三聚氰胺-脲醛树脂共混技术制备而成，制备方法包括：采用球磨法在振荡频率为10Hz时处理40min，得到木质素粉末；再通过与甲醛溶液和固体碱物质进行加成反应形成羟甲基化木质素；将羟甲基化木质素按40wt％的比例与MUF树脂均匀混合，制得低甲醛的木质素-三聚氰胺脲醛树脂胶黏剂。
木质单板表面等离子体改性工艺具体包括：采用常压低温介质阻挡放电等离子体技术，对木质单板进行改性处理，利用等离子体的刻蚀作用，改变单板表面微观结构。
实施例5
同实施例2，不同的是其中，胶合板层是由木段旋切成单板或由木方刨切成薄木，再用胶黏剂胶合而成的两层或两层以上的多层单板材料，并使相邻层单板的纤维方向互相垂直胶合而成；单板材料为木质单板表面等离子体改性后的单板。
其中，胶黏剂为羟甲基化木质素和三聚氰胺-脲醛树脂共混技术制备而成，制备方法包括：采用球磨法在振荡频率为50Hz时处理80min，得到木质素粉末；再通过与甲醛溶液和固体碱物质进行加成反应形成羟甲基化木质素；将羟甲基化木质素按20wt％的比例与MUF树脂均匀混合，制得低甲醛的木质素-三聚氰胺脲醛树脂胶黏剂。
木质单板表面等离子体改性工艺具体包括：采用常压低温介质阻挡放电等离子体技术，对木质单板进行改性处理，利用等离子体的刻蚀作用，改变单板表面微观结构。
实施例6
同实施例3，不同的是其中，胶合板层是由木段旋切成单板或由木方刨切成薄木，再用胶黏剂胶合而成的两层或两层以上的多层单板材料，并使相邻层单板的纤维方向互相垂直胶合而成；单板材料为木质单板表面等离子体改性后的单板。
胶黏剂为羟甲基化木质素和三聚氰胺-脲醛树脂共混技术制备而成，具体是采用球磨法在振荡频率为20Hz时处理60min，得到木质素粉末；再通过与甲醛溶液和固体碱物质进行加成反应形成羟甲基化木质素；将羟甲基化木质素按30％的比例与MUF树脂均匀混合，制得低甲醛的木质素-三聚氰胺脲醛树脂胶黏剂。
木质单板表面等离子体改性工艺具体包括：采用常压低温介质阻挡放电等离子体技术，对木质单板进行改性处理，利用等离子体的刻蚀作用，改变单板表面微观结构。
请参阅图1-6，一种实木复合地板，包括复合板材1、卡块2和卡槽3，其特征在于：复合板材1的一侧与卡块2一体成型，卡槽3开设于复合板材1上相对于卡块2的一侧，卡块2与卡槽3相匹配，多个本发明实木复合地板之间可以相互嵌套固定，通过将其中一个实木复合地板上的卡块2插入另外一个实木复合地板上的卡槽3，实现多个本发明实木复合地板之间的连接固定；
其中，卡块2上开设有直角卡槽21，卡块2靠近直角卡槽21的位置一体成型有梯形凸块22，卡块2与复合板材1的底部连接处开设有条形槽23，直角卡槽21与条形槽23均为贯穿式，当两个本发明的实木复合地板连接后，直角凸块31会插入直角卡槽21内，梯形凸块22会插入梯形槽32内，条形凸块33会插入条形槽23内，三组销槽相互匹配相互作用，提高实木复合地板连接的稳定性，其中，梯形凸块22与梯形槽32相互作用，有效的防止实木复合地板之间纵向交错位移，直角凸块31与直角卡槽21配合，条形凸块33与条形槽23配合，可以有效的防止实木复合地板之间横向位移；
其中，复合板材1靠近卡槽3的一侧固定连接有直角凸块31，复合板材1靠近卡槽3的一侧开设有梯形槽32，复合板材1靠近卡槽3的一侧一体成型有条形凸块33。
具体的，请参阅图4，复合板材1包括底板11、石塑PVC12、耐磨片13、树脂膜14和UV耐磨漆膜15，石塑PVC12粘接于底板11上，耐磨片13粘接于石塑PVC12上，树脂膜14粘接于耐磨片13上，UV耐磨漆膜15粘接于树脂膜14上，底板11为实木单板或多层板胶合板，石塑PVC12用于提高实木复合地板强度，耐磨片13以及UV耐磨漆膜15可以提升本发明实木复合地板的耐磨强度。
具体的，请参阅图2，底板11上开设有内槽112，内槽112内开设有两个对称设置的放置槽113，底板11上开设有边槽111，底板11与石塑PVC12之间即内槽112内可以填充干粉灭火剂，放置槽113内放置防火胶带包裹的硝化甘油、硫磺以及木炭的混合物。
具体的，请参阅图3，石塑PVC12上一体成型有两个对称设置的连板121，石塑PVC12的底部开设有十字槽122，连板121粘接于边槽111内，十字槽122内放置十字型引线，引线底端穿过干粉灭火剂插入防火胶带内部，当火灾将石塑PVC12点燃后，点燃引线，产生爆破力，将干粉灭火剂喷至周围，达到灭火的效果。
具体的，请参阅图1、图5和图6，直角凸块31与直角卡槽21相匹配，梯形凸块22与梯形槽32相匹配，条形槽23与条形凸块33相匹配，卡块2插入卡槽3后可以紧密贴合，提高整体稳定性。
具体的，请参阅图5，梯形凸块22的左下角边角角度大于九十度小于一百五十度，方便卡块2插入卡槽3内。
工作原理：多个本发明实木复合地板之间可以相互嵌套固定，通过将其中一个实木复合地板上的卡块2插入另外一个实木复合地板上的卡槽3，实现多个本发明实木复合地板之间的连接固定，当两个本发明的实木复合地板连接后，直角凸块31会插入直角卡槽21内，梯形凸块22会插入梯形槽32内，条形凸块33会插入条形槽23内，三组销槽相互匹配相互作用，提高实木复合地板连接的稳定性，其中，梯形凸块22与梯形槽32相互作用，有效的防止实木复合地板之间纵向交错位移，直角凸块31与直角卡槽21配合，条形凸块33与条形槽23配合，可以有效的防止实木复合地板之间横向位移；同时，连接时，可以将卡块2倾斜插入卡槽3内，轻晃卡块2，即可将卡块2方便的完全匹配的贴合插入卡槽3内，连接方便快速。
对比例1
一种高分子实木复合地板，包括PVC板和实木板皮，所述PVC板与实木板皮胶合固定为一体；所述PVC板由以下重量份的原料制成：PVC树脂130份、碳酸钙粉320份、PE腊1.5份、钙锌稳定剂5.5份、ACR-401 12份、硬脂酸4.5份。实木板皮的厚度为1mm，含水量为3％。
上述高分子实木复合地板的制备方法包括以下步骤：
(1)PVC板的制备：
按配方比称取PVC树脂、碳酸钙粉、PE腊、钙锌稳定剂、ACR-401、硬脂酸，将上述原料一起加入混料机中混合均匀，得混合料；将混合料送入双螺杆挤出机中进行挤出，得PVC板；
(2)高分子实木复合地板的制备：将所述PVC板上端面滚涂环保胶水，再贴合上实木板皮，然后置于冷压机中压制10h，再进行UV滚涂处理，最后分切开槽，即得。
对本发明实施例1-6和对比例1中的高分子实木复合地板的尺寸变化率进行测试，测试条件为：在80℃的条件下放置6h。测定得到的尺寸变化率如表1所示：
表1尺寸变化率
以上数据可看出：
1、实施例1-6制备得到的高分子实木复合地板的加热尺寸变化率小，远小于对比例1和一般实木复合地板的尺寸变化率(一般实木复合地板的尺寸变化率均大于0.25％)。
2、实施例1-6制备得到的高分子实木复合地板的加热翘曲度小，远小于对比例1和一般实木复合地板的尺寸变化率；
3、实施例1-6制备得到的高分子实木复合地板的剥离强度平均值较大，远大于对比例1和一般实木复合地板的剥离强度平均值；
4、本发明高分子实木复合地板在使用过程中不变形，不开裂，性能稳定，使用寿命长。
本具体实施例仅仅是对本发明的解释，其并不是对本发明的限制，本领域技术人员在阅读完本说明书后可以根据需要对本实施例做出没有创造性贡献的修改，但只要在本发明的权利要求范围内都受到专利法的保护。
Claims (10)
1.一种高分子实木复合地板，其特征在于：包括SPC石塑层，所述SPC石塑层下方设置有形成地板主体的实木单板层或胶合板层；所述高分子实木复合地板的理化性能指标为：色牢度≥6级；剥离强度平均值≥75(N/50mm)，耐污染≥5级，加热尺寸变化率≤0.025％，加热翘曲度≤2.0mm，含水率为6-10％。
2.根据权利要求1所述的一种高分子实木复合地板，其特征在于：所述SPC石塑层上方从上而下依次设置有UV层、耐磨片层和树脂膜层。
3.根据权利要求2所述的一种高分子实木复合地板，其特征在于：所述高分子实木复合地板的理化性能指标为：弹性模量≥4000MPa，静曲强度≥30MPa，表面耐磨≤0.08g/100r，漆膜硬度≥2H，总挥发物限量≤40g/㎡，可溶性镉(Cd)≤20mg/㎡，可溶性铅(Pb)≤20mg/㎡，甲醛释放量≤0.050mg/m3，冷热翘曲度≤2.0mm，防霉性≤1级。
4.根据权利要求3所述的一种高分子实木复合地板，其特征在于：所述高分子实木复合地板的理化性能指标为：所述高分子实木复合地板的开槽尺寸指标为：
直角度qmax≤0.1mm；边缘不直度smax≤0.15mm；
翘曲度：宽度方向凸翘度fw≤0.20％；宽度方向凹翘曲度fw≤0.15％；长度方向凸翘度fl≤0.5％，长度方向凹翘曲度fl≤0.25％。
5.根据权利要求4所述的一种高分子实木复合地板，其特征在于：所述高分子实木复合地板的理化性能指标为：当所述SPC石塑层下方的地板主体为胶合板层时，胶合板的性能指标为：含水率为10-12％，弹性模量≥4000MPa，静曲强度≥40MPa，甲醛释放量≤0.025mg/m3。
6.根据权利要求5所述的一种高分子实木复合地板，其特征在于：所述高分子实木复合地板的理化性能指标为：所述SPC石塑层的理化性能指标要求为：色牢度≥6级；剥离强度平均值≥75(N/50mm)，耐污染≥5级，防霉性≤1级，加热尺寸变化率≤0.025％，加热翘曲度≤2.0mm，冷热翘曲度≤2.0mm，可溶性镉(Cd)≤20mg/㎡，可溶性铅(Pb)≤20mg/㎡，甲醛释放量≤0.025mg/m3。
7.一种根据权利要求1-6任一项所述高分子实木复合地板的制备工艺，其特征在于包括：
(1)SPC层制备；
(2)实木单板层或胶合板层制备；
(3)复合压贴：将SPC层与实木单板层或胶合板层冷压贴合；
(4)一次平衡处理；
(5)分切；
(6)二次平衡处理；
(7)开槽；
(8)UV层制备。
8.一种根据权利要求7所述高分子实木复合地板的制备工艺，其特征在于SPC层制备包括以下步骤：
S1,原料配比：按重量份包括聚氯乙烯树脂粉80-90、碳酸钙160-180、钛酸钙10-30、内润滑剂0.6-0.8、聚乙烯蜡1.0-1.2、氯化聚乙烯2-4、丙烯酸酯0.8-1.5、复合润滑剂0.6-0.9、液体钡锌稳定剂2-3；
S2,将上述原料投入高速搅拌机进行混料升温，再经低速搅拌降温，然后经挤出机挤出。
9.根据权利要求8所述高分子实木复合地板的制备工艺，其特征在于所述步骤(3)复合压贴工艺参数包括；冷压温度10-45℃,压力：15±0.5MPa,时间：40-45分钟,其中无压力停放时间为控制在20分钟之内,压贴产品必须经过72小时存放进行后固化处理。
10.根据权利要求9所述高分子实木复合地板的制备工艺，其特征在于所述步骤(6)二次平衡处理包括将分切后的板材，按照“#”进行码放，要进行防潮防护，四周要使用缠绕膜缠绕起来，必须经过72小时以上平衡处理才能够进入开槽工序。
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Application publication date: 20211019 |