CN114293732A - Composite floor and production process thereof - Google Patents
Composite floor and production process thereof Download PDFInfo
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- CN114293732A CN114293732A CN202111523344.7A CN202111523344A CN114293732A CN 114293732 A CN114293732 A CN 114293732A CN 202111523344 A CN202111523344 A CN 202111523344A CN 114293732 A CN114293732 A CN 114293732A
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Abstract
The invention has provided a composite floor and its preparation method, this floor includes the supporter of the metal material and joint mainly the buffer formed by polymer resin on the surface of the said supporter; a clamping groove is formed in the upper surface of the supporting body, and a clamping part matched with the clamping groove is formed in the buffer body in an extending mode towards the supporting body; the clamping groove is provided with a limiting component for preventing the clamping component from falling out of the clamping groove; the buffer body comprises a buffer body main body and a hard surface layer arranged on the surface of the buffer body main body; the clamping component is formed by a buffer body main body; the buffer body main body is made of foamed thermoplastic plastics, and the density of the buffer body main body is 0.8-1.2 g/cm for carrying out thin film planting; the hard surface layer is made of thermoplastic plastics, and the Shore hardness is more than 65 HD. The invention can greatly improve the bonding strength between the support body and the buffer body, and the bonding strength can not be obviously reduced when factors such as temperature, humidity and the like are changed.
Description
Technical Field
The invention relates to the technical field of building floor decoration, in particular to a composite floor.
Background
The wood-plastic floor manufactured by taking the plant fiber and the thermoplastic plastic as main raw materials has the advantages of environmental protection, wood replacement, easy maintenance and the like, and more consumers select the wood-plastic floor to replace the traditional wood floor. The wood-plastic floor is usually prepared by mixing hot-melt high polymer materials such as polyethylene and the like, wood powder and an auxiliary agent, and the prepared wood-plastic floor has the problems of low strength, easy bending and deformation, flammability and the like due to the strength defect of the materials.
In order to solve the problems, the production scheme provides that the aluminum alloy is used as the base material, the wood plastic material is used as the surface layer floor structure, the aluminum alloy base material is used for ensuring the physical strength of the floor, the mechanical property and the bearing capacity of the floor are improved, and meanwhile, the wood plastic material on the surface of the aluminum alloy base material is used for enabling the floor to have the characteristics of water resistance, wear resistance, elastic buffer effect on the surface layer and the like. For example, patent document CN201410246694.7 discloses an aluminum-plastic composite floor, which is provided with an EVA hot melt adhesive layer, a PVC layer, a pattern layer and a wear layer on the upper surface of an aluminum alloy substrate. Although above-mentioned patent adopts the hot melt adhesive to improve the bonding strength between wood-plastic and the aluminum alloy, but bonding strength relies on the size of cohesion between hot melt adhesive and the aluminum alloy substrate layer, along with the use on floor, the hot melt adhesive can age gradually and lead to the bonding effect to reduce, has caused certain influence to the life on floor.
Disclosure of Invention
In order to solve the above problems, the present invention provides a composite floor, in which a metal base material and a clad material are combined with each other to form a high-strength binding force, thereby prolonging the service life of the floor.
The invention adopts the following technical scheme:
a composite floor comprises a support body made of metal materials and a buffer body which is clamped on the surface of the support body and mainly comprises polymer resin; a clamping groove is formed in the upper surface of the supporting body, and a clamping part matched with the clamping groove is formed in the buffer body in an extending mode towards the supporting body; the clamping groove is provided with a limiting component for preventing the clamping component from falling out of the clamping groove; the buffer body comprises a buffer body main body and a hard surface layer arranged on the surface of the buffer body main body; the clamping component is formed by a buffer body main body; the buffer body main body is made of foamed thermoplastic plastics, and the density of the buffer body main body is 0.8-1.2 g/cm for carrying out thin film planting; the hard surface layer is made of thermoplastic plastics, and the Shore hardness is more than 65 HD.
In the existing technical scheme, the base material and the coating layer made of metal materials are generally attached in a manner of base material plane-coating layer plane, the bonding strength between the two planes completely depends on the compatibility of the materials between the base material and the coating layer, and the strength of the compatibility mainly depends on the physical adsorption strength of the high polymer material forming the coating layer on the surface of the metal base material, the chemical bond strength formed by the high polymer material and the metal atoms on the surface of the base material, and the like. The physical adsorption strength and the chemical bond strength are highly related to environmental factors, the physical adsorption strength and the chemical bond stability have large fluctuation under different environmental conditions such as cold, heat, dryness, humidity and the like, the floor can undergo multiple rounds of environmental changes in the long-term use process, and the bonding structure between the metal base material and the coating layer is difficult to be prevented from being damaged in the multiple rounds of environmental changes. And the peeling phenomenon is easy to occur between the base material and the coating layer which are combined in a plane-plane mode, thereby further influencing the service life of the floor.
The upper surface of the supporting body made of the metal material is provided with the clamping groove, the buffer body extends towards the direction of the supporting body to form the clamping part, when the clamping part is matched with the clamping groove, the limiting part arranged in the clamping groove can prevent the clamping part from being separated from the clamping groove, so that the buffer body and the supporting body form macroscopic physical clamping, and the buffer body and the supporting body can be continuously and stably combined because the physical clamping is basically not influenced by environmental factors. To make buffer body and supporter separation, need joint part fracture from buffer body and break away from, but joint part is by buffer body integrated into one piece, consequently makes joint part fracture and break away from required external force and need reach higher level, and this external force size is far away from the normal application scope on floor, therefore the floor can keep the stable complex of buffer body and supporter in the use. In addition, the buffer body comprises two parts, a buffer body main body which is in clamping combination with the support body and a hard surface layer formed on the surface of the buffer body main body. The buffering body main part is made by expanded material, expanded material can take place the inflation because the effect volume of foamer from extruding the fashioned in-process, in floor production process, extrude expanded material behind the supporter surface, expanded material can fill to the joint groove in, the difference of non-expanded material is, fill back in the joint groove, thereby expanded material can take place self inflation and form closely cooperating with the cell wall in joint groove, and the pressure that produces through the foaming process makes the joint part that forms and joint groove have stable joint effect, the joint part is difficult for becoming flexible in the joint groove. If adopt non-expanded material to make the buffering body main part, then appear filling incomplete problem easily after non-expanded material fills to the joint groove, when leaving gas pocket, cavity in the joint groove, the joint intensity of joint part and joint groove will obviously reduce. Meanwhile, in the market, a composite flooring made of metal and polymer materials is accepted by consumers, and more beautiful and natural appearance is required in addition to durability, so that it is sometimes required to form embossed patterns on the surface of the flooring to simulate wood grains or other pattern shapes. In addition, some occasions require the floor to have a non-slip effect, so that a non-slip groove is formed on the surface of the floor by embossing. For the aluminum-plastic composite floor, the embossing is obtained by processing the coating layer through the embossing roller, and in order to achieve a good embossing effect, the sufficient thickness of the coating layer is generally required to ensure that the pattern on the embossing roller can form a clear pattern after processing the coating layer. The foam material has low density and certain compressibility, so that embossed patterns are more easily formed when the foam material is processed by the embossing roller, and the embossed patterns are not easy to deform and disappear due to the self-resilience characteristic of the resin material. However, in addition to the above advantages, the foam material has the problem of insufficient surface physical properties, and is easily scratched and worn, so the invention compounds a hard surface layer formed by thermoplastic plastics with shore hardness of more than 65HD on the surface of the main body of the buffer body formed by the foam material to improve the surface physical properties of the floor.
Preferably, the material of the cushion body is rigid foamed polyvinyl chloride, and the material of the rigid surface layer is ASA. It should be noted that "the material of the cushion body is rigid foamed polyvinyl chloride" means that the main resin component in the composition of the cushion body is polyvinyl chloride, and besides polyvinyl chloride, a small amount of other resin materials with a content lower than that of polyvinyl chloride can be added, or filler materials such as wood flour and the like can be added, and some additives such as antioxidants, lubricants and the like commonly used in the resin processing process can be added, and the addition of the above materials is the prior art commonly used in the field, and therefore, the description is omitted. The hard surface layer is made of ASA in the same way.
In order to further improve the bonding strength between the buffer body and the support body, an adhesive layer can be arranged between the support body and the buffer body. The adhesive layer can be a high molecular material with self-adhesion or a hot melt adhesive, and for the convenience of co-extrusion production, the hot melt adhesive is preferably adopted. In the production process of the floor, the surface of the support body is coated with the hot melt adhesive, and then the buffer body is coated on the basis of the hot melt adhesive. In the invention, the upper surface of the supporting body is provided with the clamping groove, so that the upper surface is divided into a plane part without the clamping groove and a groove part with the clamping groove, and in the process of coating the hot melt adhesive, the plane part and the groove part are preferably coated, namely, the adhesive layer is provided with a flat adhesive part formed on the surface of the plane part and a groove adhesive part formed on the groove wall of the clamping groove. Preferably, the difference between the thicknesses of the flat glue part and the slot glue part is not more than 0.2 mm. The glue groove part formed in the clamping groove and the glue flattening part formed on the plane part are integrally formed, the hot melt glue is required to form a glue groove part which is uniform in thickness and basically consistent with the glue flattening part along the surface of the groove wall of the clamping groove, and the glue groove part is not naturally converged to form a structure with uneven thickness under the action of gravity at the groove bottom of the clamping groove.
Furthermore, the support body comprises a connecting part clamped with the buffer body and a supporting part supporting the connecting part; the connecting part is formed by integrally connecting a plurality of surface bodies and a plurality of groove bodies at intervals; the supporting part is formed by integrally connecting a layered body arranged at the bottom and a plurality of sheet-shaped bodies vertically arranged at the upper part of the layered body; the groove-shaped body comprises a middle groove-shaped body and an edge groove-shaped body, the middle groove-shaped body is arranged between two adjacent surface-shaped bodies, and the edge groove-shaped body is arranged at one side, close to the outside, of the two surface-shaped bodies, close to the outside, of the connecting part; the platy bodies are in supporting connection with the middle groove bodies in a one-to-one corresponding mode. Preferably, the middle groove-shaped body is horizontally arranged, and the edge groove-shaped body is obliquely arranged outwards.
The edge groove-shaped bodies of the invention refer to two groove-shaped bodies close to the two side edge parts of the support body, and the middle groove-shaped body refers to the rest groove-shaped bodies formed between the two edge groove-shaped bodies. The middle part of the floor plays a main structural supporting role, so the flaky bodies arranged on the supporting parts are in one-to-one corresponding supporting connection with the middle groove bodies, and the supporting parts can form a uniform supporting effect on the connecting parts.
Under the general stress condition of the floor, the stress point of the supporting body is positioned at the planar body part, then the pressure acts on the groove-shaped bodies connected with the two sides of the sheet-shaped body through the planar body, then acts on the sheet-shaped body through the groove-shaped bodies, and finally is transmitted to the laminated body through the sheet-shaped body. When pressure acts on the groove-shaped body, the groove wall of the groove-shaped body is vertically arranged relatively, so that the pressure resistance of the groove-shaped body in the vertical direction is obviously higher than that of a horizontally arranged plate structure, the connecting part between the connecting part and the supporting part is not easy to deform and break due to the pressure, and the groove-shaped body substantially plays a role similar to a stamping reinforcing rib. The bottom of the edge groove-shaped body is not connected with the sheet-shaped body, and only one side of the edge groove-shaped body is connected with the plane-shaped body, so that the structure activity of the edge groove-shaped body is far higher than that of the middle groove-shaped body, namely the edge groove-shaped body is easier to elastically deform under the action of pressure. When the floor splices each other, during the mutual butt in the side position on two adjacent floors, thereby the marginal trough-shaped can receive the ascending pressure in horizontal direction and take place elastic deformation to adapt to the mutual extrusion between the adjacent floor in the floor installation, make the installation more convenient. Preferably, the middle groove-shaped body is horizontally arranged, and the edge groove-shaped body is obliquely arranged outwards. In the intermediate trough-shaped body, two trough connecting parts which are positioned at the trough opening part and used for transitionally connecting with the planar body exist on the trough wall, and because both the trough connecting parts of the intermediate trough-shaped body are connected with the planar body, the connecting line of the two trough connecting parts is horizontal on the premise that the plane of the planar body is horizontal, so the intermediate trough-shaped body is considered to be horizontally arranged. In the case of the edge groove-shaped bodies, one of the groove-connecting portions is connected to the planar body, and the other groove-connecting portion is located lower than the planar body, so that when the two groove-connecting portions are connected, the connecting line is non-horizontal, and in terms of the overall structure, the opening of the middle groove-shaped body faces vertically upward, and the opening of the edge groove-shaped body faces obliquely upward.
Another object of the present invention is to provide a process for producing the above composite flooring, which comprises the steps of:
s1: preheating a support body made of a metal material, and conveying the support body to a processing flow channel of a mold through a tractor;
s2: the support body reaches a first processing section of the processing flow channel, and hot melt adhesive is extruded on the upper surface of the support body through a first extruder to form an adhesive layer, so that a first coating base material is obtained;
s3: the first coated substrate prepared in the step S2 reaches the second processing section of the processing flow channel, and the thermoplastic foam material is extruded on the upper surface of the first coated substrate by the second extruder to form the buffer body main body, so as to obtain a second coated substrate;
s4: the second coated substrate prepared in the step S3 reaches a third processing section of the processing flow channel, and a thermoplastic plastic with shore hardness of more than 65HD is coated on the upper surface of the second coated substrate through a third extruder to form a hard surface layer, so as to obtain a rectangular plate;
s5: the prototype plate manufactured in the step S4 is transported out of the die, and the composite floor is obtained after shaping and embossing treatment;
the upper runner wall of the first processing section corresponding to the upper surface of the support body is provided with a plurality of protruding pieces, and each protruding piece corresponds to one clamping groove; when the supporting body reaches the first processing section, the protruding part is embedded into the clamping groove, a distance is reserved between the outer contour of the protruding part and the groove wall of the clamping groove, and an adhesive layer filling area is formed.
In the invention, the foaming material is required to enter the clamping groove and form a clamping part structure, however, in the process of coating the hot melt adhesive on the surface of the support body by adopting a conventional extrusion process, the hot melt adhesive can continuously flow into the clamping groove under the extrusion pressure and is accumulated from the bottom of the groove, so that the space in the clamping groove is gradually reduced and the clamping groove is finally filled, and when the buffer body is coated in the second processing section, the foaming material forming the buffer body can not enter the clamping groove and can not form the clamping part finally. Therefore, the plurality of protruding parts are arranged on the upstream channel wall of the first processing section, after the protruding parts are embedded into the clamping groove, a space is reserved between the outer outline of the protruding parts and the groove wall of the clamping groove, and an adhesive layer filling area is formed, the hot melt adhesive can only fill the adhesive layer filling area to form the groove adhesive part with uniform thickness, after the first coating base material is led out of the first processing section, the protruding parts are separated from the clamping groove, and a cavity for filling the foaming material is formed in the clamping groove.
It is still another object of the present invention to provide a mold suitable for the above composite floor manufacturing process.
The mold for producing the composite floor comprises a plurality of mold blocks which are assembled, wherein the middle parts of the mold blocks form through holes to jointly form a complete processing flow channel; the processing flow channel is sequentially provided with a first processing section, a second processing section and a third processing section along the conveying direction of the base material layer, a hot melt adhesive flow channel is arranged on a die block where the first processing section is located, and the hot melt adhesive flow channel is connected with the first extruder and used for coating hot melt adhesive on the surface of the support body to form an adhesive layer; the die block where the second processing section is located is provided with a foaming material runner, and the foaming material runner is connected with the second extruder and used for coating a foaming material on the surface of the support body to form a buffer body main body; a surface layer runner is arranged on the die block where the third processing section is located, and the surface layer runner is connected with a third extruder and used for coating hot-melt plastics on the surface of the support body to form a hard surface layer; the calibers of the first processing section, the second processing section and the third processing section are sequentially increased to adapt to thickness change in the floor coating process, and more specifically, the upper wall setting height of the through opening is sequentially increased while the lower wall is unchanged; the opening upper wall of the mould piece at first processing section place is equipped with a plurality of bellyings, and the position one-to-one of bellyings position and the joint groove position of supporter.
In the technical scheme of the invention, the one-to-one correspondence between the setting position of the protruding part and the position of the clamping groove of the support body means that when the support body is conveyed to the first processing section, the protruding part can be embedded into the clamping groove formed on the upper surface of the support body, the external outline shape of the protruding part is consistent with the outline shape of the groove wall of the clamping groove, and the difference is that the size of the external outline shape of the protruding part is smaller than that of the groove wall, so that a certain interval area is formed between the protruding part and the groove wall of the clamping groove, and the interval area is an adhesive layer filling area; through the restriction of the protruding piece, the joint groove can not be filled up when the hot melt adhesive coats the upper surface of the support body, but the groove glue part with uniform thickness is only formed on the groove wall of the joint groove.
In summary, the following beneficial effects can be achieved by applying the technical scheme of the invention:
1. in the invention, the clamping groove is formed on the upper surface of the supporting body, the buffer body is provided with the clamping part extending towards the direction of the supporting body, the buffer body and the supporting body can be firmly connected through the matching of the clamping groove and the clamping part, and the connection strength is basically not influenced by environmental factors such as temperature, humidity and the like.
2. According to the floor, the buffer body main body is made of the foaming material, the foaming material can be filled into the clamping groove after being extruded to the surface of the support body in the floor production process, the foaming material can expand to be tightly matched with the groove wall of the clamping groove after being filled into the clamping groove, the formed clamping part and the clamping groove have a stable clamping effect through pressure generated in the foaming process, the clamping part is not easy to loosen in the clamping groove, and meanwhile, the non-foaming hard plastic surface layer is arranged on the surface of the foamed support body main body, so that the problem that the surface physical property of the foaming material is insufficient is solved.
3. In the invention, when the pressure applied to the floor acts on the groove-shaped body through the planar body, the groove wall of the groove-shaped body is arranged vertically relatively, so that the pressure resistance of the groove-shaped body in the vertical direction is obviously higher than that of a horizontally arranged plate structure, the connecting part between the connecting part and the supporting part is not easy to deform and break due to the pressure, and the groove-shaped body substantially plays a role similar to a stamping reinforcing rib.
4. The invention provides a special die for producing a composite floor, which is used for arranging a plurality of protrusions on the upper groove wall of a first processing section of a support body, wherein the surface of the support body is coated with an adhesive layer; when the supporter reachd first processing section, bellying embedding to joint groove in, leave the interval and form the gluing layer filling area between the cell wall in bellying outside profile and joint groove, when gluing layer cladding, the hot melt adhesive can only fill gluing layer filling area, and can not fill the joint groove and be full of, make the buffer body of follow-up cladding can form the joint part smoothly.
Drawings
FIG. 1 is a schematic view and a partially enlarged view of a composite floor in example 1;
FIG. 2 is a schematic view showing a structure of a support of the composite floor of embodiment 1;
FIG. 3 is a schematic sectional view of the mold in example 2;
fig. 4 is a schematic view and a partial enlarged view of a matching structure of the substrate layer and the fourth mold block in embodiment 2;
FIG. 5 is a schematic view of the structure of the support in comparative example 1;
in the figure, 1-a support body, 2-a buffer body, 3-an adhesive layer, 4-a mould, 11-a connecting part, 12-a supporting part, 21-a buffer body main body, 22-a hard surface layer, 31-a flat adhesive part, 32-a groove adhesive part, 41-a first processing section, 41-a second processing section, 43-a third processing section, 101-a clamping groove, 102-a limiting part, 111-a planar body, 112-a groove-shaped body, 121-a pile body, 122-a sheet body, 211-a clamping part, 411-a bulge and 412-an adhesive layer filling area.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious 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.
In the description of the present invention, it should be noted that the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer", etc., indicate orientations or positional relationships based on the orientations or positional relationships shown in the drawings, and are only for convenience of description and simplicity of description, but do not indicate or imply that the device or element being referred to must have a particular orientation, be constructed and operated in a particular orientation, and thus, should not be construed as limiting the present invention; unless expressly stated or limited otherwise, the terms "mounted," "connected," and "connected" are intended to be inclusive and mean, for example, that they may be fixedly connected, detachably connected, or integrally connected; can be mechanically or electrically connected; they may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meanings of the above terms in the present invention can be understood in specific cases to those skilled in the art.
Example 1
As shown in fig. 1, the present embodiment provides a composite floor, which includes a supporting body 1, a buffering body 2 compounded on the upper surface of the supporting body 1, and an adhesive layer 3 disposed between the supporting body 1 and the buffering body 2.
Specifically, as shown in fig. 2, the supporting body 1 includes a connecting portion 11 for forming a snap-fit connection with the buffer body, and a supporting portion 12 disposed below the connecting portion for supporting the connecting portion. The supporting part is composed of a horizontally arranged laminar body 121 and a longitudinally arranged sheet-shaped body 122, the lower end of the sheet-shaped body 122 is connected with the upper surface of the laminar body, the upper end of the sheet-shaped body is connected with the lower surface of the connecting part, and a cavity is formed between the two adjacent sheet-shaped bodies. The connecting portion is formed by integrally connecting a plurality of planar bodies 111 and a plurality of groove-shaped bodies 112 at intervals, and all the planar bodies are on the same plane. The slot body is internally provided with a clamping groove 101, the notch part of the clamping groove is provided with a limiting part 102, and the clamping part 102 enables the notch part of the clamping groove to form a narrow opening relative to the inside of the clamping groove. The two groove-shaped bodies positioned at the two sides of the supporting body are obliquely arranged outwards, and the groove-shaped body positioned at the middle part is horizontally arranged. Each sheet 122 of the support is connected to the lower surface of one of the trough-like bodies 101 located in the middle, and the sheet 122 is not provided on the lower surface of the trough-like body located on both sides of the support.
As shown in fig. 1, the support body includes a cushion body 21 made of a rigid foam material and a rigid skin layer 22 made of a thermoplastic plastic, and both sides of the adhesive layer 3 are bonded to the support body 1 and the cushion body 21, respectively. The buffer body main part to the direction extension of supporter 1 be formed with joint groove 101 matched with joint part 211, joint part and joint groove form the cooperation back, and stop part 102 can prevent that joint part from deviating from in the joint groove.
The adhesive layer 3 forms a coating layer with uniform thickness along the upper surface contour of the connecting part 11, specifically, a planar glue leveling part 31 is formed on the surface adhesive layer of the planar body 111 of the connecting part 11, a groove glue part 32 with uniform thickness along the groove wall contour is formed in the clamping groove 101 of the groove-shaped body 112 of the connecting part, the glue leveling part 31 and the groove glue part 32 are integrally formed, and the thickness difference between the glue leveling part and the groove glue part is less than 0.2 mm.
Example 2
This example provides a production mold for the aluminum-plastic composite floor in example 1. As shown in fig. 3, the production mold 3 is assembled by a plurality of mold blocks, and for convenience of description, the mold blocks are respectively named as first to seventh mold blocks from left to right, and the substrate layer conveying direction is from the seventh mold block to the first mold block. The middle parts of the seven mould blocks form through holes, and the through holes of the seven mould blocks form a complete processing flow channel together. The processing channel is provided with a first processing section 41, a second processing section 42 and a third processing section 43 in sequence along the conveying direction of the substrate layer, wherein the first processing section is formed by the through opening of the fourth die block, the second processing section is formed by the through opening of the third die block, and the third processing section is formed by the through openings of the first die block and the second die block. A hot melt adhesive flow passage 41a is formed in the fifth die block, is connected with the first extruder and is used for coating the hot melt adhesive on the surface of the support body to form an adhesive layer; a foaming material flow passage 42a is arranged on the fourth die block, is connected with the second extruder and is used for coating a foaming material on the surface of the support body to form a buffer body main body; the third die block is provided with a surface layer runner 43a, which is connected to the third extruder and used for coating the surface of the support body with hot-melt plastic to form a hard surface layer. The hot melt adhesive runner and the processing runner are communicated at the position where the fourth die block and the fifth die block are connected, namely, the hot melt adhesive runner extrudes hot melt adhesive from the tail end of the fifth die block, and the hot melt adhesive coats the upper surface of the support body in the port (namely, the first processing section) of the fourth die block. The diameters of the first processing section, the second processing section and the third processing section are sequentially increased to adapt to thickness change in the floor covering process, and more specifically, the upper wall setting height of the through hole is sequentially increased while the lower wall is unchanged.
As shown in fig. 3 and 4, the upper walls of the through holes of the fourth mold block and the fifth mold block are provided with a plurality of protruding members 411, the protruding members extend from the starting end of the fifth mold block to the tail end of the fourth mold block, the positions of the protruding members are in one-to-one correspondence with the positions of the clamping grooves 101 of the support body, when the support is transferred to the fifth mold block, the protrusion 411 is inserted into the engaging groove 101 formed on the upper surface of the support, the outer contour shape of the protrusion is identical to the groove wall contour shape of the catching groove 101, except that the outer contour shape of the protrusion is smaller in size than the groove wall contour shape, so that a certain spaced area is formed between the protrusion 411 and the groove wall of the catching groove 11, the spacing area is an adhesive layer filling area 412, and when the support body is conveyed to the fourth mold block, the first extruder extrudes hot melt adhesive on the upper surface of the support body through the hot melt adhesive flow passage 41a, and the hot melt adhesive fills the adhesive layer filling area 412. Through the restriction of the protruding piece, the joint groove can not be filled up when the hot melt adhesive coats the upper surface of the supporting body, but the groove glue part with uniform thickness is only formed on the groove wall of the joint groove, when the supporting body is conveyed to the second processing section (namely, the third die block), the protruding piece is separated from the joint groove, and a cavity for filling the foaming material is formed in the joint groove.
Example 3
The embodiment provides a process for producing the aluminum-plastic composite floor in the embodiment 1 by using the mold in the embodiment 2, which specifically comprises the following steps:
s1: preparing a support body made of an aluminum alloy, wherein the structure of the support body is as shown in embodiment 1; the support body is preheated for 15s by a heating box at 130 ℃, and then conveyed into a processing runner of a mold by a tractor; the mold structure is as in example 2;
s2: after the support body reaches a first processing section of the processing flow channel, extruding polyurethane hot melt adhesive on the upper surface of the support body through a first extruder to form an adhesive layer, and obtaining a first coating base material;
s3: the first coated base material prepared in the step S2 reaches a second processing section of the processing flow channel, and a polyvinyl chloride foamed material is extruded on the upper surface of the first coated base material by a second extruder to obtain a second coated base material;
s4: the second coated substrate prepared in the step S3 reaches a third processing section of the processing flow channel, and ASA plastic is coated on the upper surface of the second coated substrate by a third extruder to form a hard surface layer, so as to obtain a rectangular plate;
s5: the prototype plate manufactured in the step S4 is transported out of the die, and the composite floor is obtained after shaping and embossing treatment;
comparative example 1
The comparative example provides another production process of the aluminum-plastic composite floor, which specifically comprises the following steps:
s1: preparing a support body made of aluminum alloy, wherein the structure of the support body is shown in FIG. 5, and the difference from the embodiment 1 is that the support body is not provided with a clamping groove in the comparison example; the support body is preheated for 15s by a heating box at 130 ℃, and then conveyed into a processing runner of a mold by a tractor; the mold structure was substantially the same as that of example 2 except that no protrusion was provided on the upper wall of the through opening of the fourth mold block;
s2: after the support body reaches a first processing section of the processing flow channel, extruding polyurethane hot melt adhesive on the upper surface of the support body through a first extruder to form an adhesive layer, and obtaining a first coating base material;
s3: the first coated base material prepared in the step S2 reaches a second processing section of the processing flow channel, and a polyvinyl chloride foamed material is extruded on the upper surface of the first coated base material by a second extruder to obtain a second coated base material;
s4: the second coated substrate prepared in the step S3 reaches a third processing section of the processing flow channel, and ASA plastic is coated on the upper surface of the second coated substrate by a third extruder to form a hard surface layer, so as to obtain a rectangular plate;
s5: the prototype plate manufactured in the step S4 is transported out of the die, and the composite floor is obtained after shaping and embossing treatment;
comparative example 2
The comparative example provides another production process of the aluminum-plastic composite floor, which specifically comprises the following steps:
s1: preparing a support body made of an aluminum alloy, wherein the structure of the support body is as shown in embodiment 1; the support body is preheated for 15s by a heating box at 130 ℃, and then conveyed into a processing runner of a mold by a tractor; the mold structure is as in example 2;
s2: after the support body reaches the first processing section of the processing flow channel, the hot melt adhesive is not extruded, and the support body is kept in a non-coating state;
s3: the support body reaches a second processing section of the processing flow channel, and a polyvinyl chloride foaming material is extruded on the upper surface of the first coating base material through a first extruder to obtain a first coating base material;
s4: the first coated substrate prepared in the step S3 reaches the third processing section of the processing flow channel, and ASA plastic is coated on the upper surface of the first coated substrate by a second extruder to form a hard surface layer, so as to obtain a prototype plate;
s5: the prototype plate manufactured in the step S4 is transported out of the die, and the composite floor is obtained after shaping and embossing treatment;
comparative example 3
This comparative example provides another process for manufacturing an aluminum-plastic composite flooring, which has substantially the same steps as example 3, except that a PVC non-foamed material containing no foaming agent is extruded to the surface of the first coated substrate by the second extruder when the first coated substrate reaches the second processing stage.
The flooring obtained in example 3 and comparative examples 1 to 3 were compared by experiments.
Bonding strength test:
(1) according to the test method of GB/T17657-2013, a steel chuck with the size of 20mm x 20mm is adhered to a sample by using an HY-914 quick adhesive, the adhesive layer is cut along the outline of the steel chuck, after the steel chuck is firmly adhered, the steel chuck is pulled upwards by using a tension meter along the direction vertical to the plane of the plate, or the steel chuck is placed downwards on the steel chuck to suspend a heavy object, the gravity of the heavy object is recorded, the maximum tensile force (N) or the maximum gravity before the buffer body is delaminated from the aluminum alloy support body is recorded, the maximum tensile force is recorded as F, the adhesion strength is P = F/S, and S is the area of the steel chuck. The results are reported in table 1 under the column a for bond strength.
(2) Placing a sample in a water bath environment at 60 ℃ for 12H, then placing the sample in an ultralow-temperature refrigerator at-35 ℃ for 24H freezing, wherein the process forms a period, and placing the sample in 2H at the normal temperature of 23 +/-2 ℃ after circulating for five periods and carrying out drying treatment; the samples were then tested according to the method in (1). The results are reported in table 1 under the column B for bond strength.
TABLE 1
As can be seen from table 1, the four-layer aluminum-plastic composite floor prepared in example 3 of the present invention has high bonding strength, and the bonding strength decreases less after being subjected to cooling and heating cycles at 60 ℃ and-35 ℃, and still maintains high bonding strength. The difference between the comparative example 1 and the example 3 is only that the support body is replaced, the upper surface of the support body in the comparative example 1 is a flat non-groove structure, and as can be seen from the data in the table 1, the bonding strength of the comparative example 1 is greatly reduced compared with the example 3, and the bonding strength is also greatly reduced after being subjected to the cold and hot treatment. The difference between the comparative example 2 and the example 3 is that the adhesive layer is not used, the cushion body and the support body are directly compounded, and from the experimental result, the bonding strength is also obviously reduced compared with the example 3, however, after the multi-round cold and hot treatment, the bonding strength is not greatly reduced. It can be seen from the combination of comparative example 1 and comparative example 2 that the arrangement of the clamping groove and the clamping part can greatly improve the problem that the bonding strength of the buffer body and the support body is easily affected by the environment, and the problem that the floor quality is caused by the great reduction of the bonding strength after the floor is used for a long time is avoided. The difference between the comparative example 3 and the example 3 is only that the material of the main body of the cushion body is non-foamed polyvinyl chloride, compared with the comparative examples 1 and 2, the comparative example 3 has higher bonding strength, but the bonding strength is less than that of the example 3, because the clamping part formed by the main body of the cushion body made of the foamed material can form more stable clamping with the clamping groove.
The above description is only a preferred embodiment of the present invention, and all equivalent changes and modifications made in accordance with the claims of the present invention should be covered by the present invention.
Claims (10)
1. A composite floor comprises a support body made of metal materials and a buffer body which is clamped on the surface of the support body and mainly comprises polymer resin; a clamping groove is formed in the upper surface of the supporting body, and a clamping part matched with the clamping groove is formed in the buffer body in an extending mode towards the supporting body; the clamping groove is provided with a limiting component for preventing the clamping component from falling out of the clamping groove; the buffer body comprises a buffer body main body and a hard surface layer arranged on the surface of the buffer body main body; the clamping component is formed by a buffer body main body; the buffer body main body is made of foamed thermoplastic plastics, and the density of the buffer body main body is 0.8-1.2 g/cm for carrying out thin film planting; the hard surface layer is made of thermoplastic plastics, and the Shore hardness is more than 65 HD.
2. A composite floor according to claim 1, characterised in that: the buffer body is arranged on the support body and comprises a buffer body and an adhesive layer arranged between the support body and the buffer body.
3. A composite floor according to claim 2, characterised in that: the adhesive layer is formed by cooling hot melt adhesive.
4. A composite floor according to claim 3, characterised in that: the gluing layer comprises a flat gluing part and a slot gluing part which are integrally connected.
5. A composite floor according to claim 4, characterised in that: the thickness difference between the glue leveling part and the glue groove part is not more than 0.2 mm.
6. A composite floor according to claim 4, characterised in that: the main body of the buffer body is made of hard foamed polyvinyl chloride; the hard surface layer is made of ASA.
7. A composite floor according to claim 4, characterised in that: the supporting body comprises a connecting part clamped with the buffer body and a supporting part for supporting the connecting part; the connecting part is formed by integrally connecting a plurality of surface bodies and a plurality of groove bodies at intervals; the supporting part is formed by integrally connecting a layered body arranged at the bottom and a plurality of sheet-shaped bodies vertically arranged at the upper part of the layered body; the groove-shaped body comprises a middle groove-shaped body and an edge groove-shaped body, the middle groove-shaped body is arranged between two adjacent surface-shaped bodies, and the edge groove-shaped body is arranged at one side, close to the outside, of the two surface-shaped bodies, close to the outside, of the connecting part; the platy bodies are in supporting connection with the middle groove bodies in a one-to-one corresponding mode.
8. A composite floor according to claim 7, characterised in that: the middle groove-shaped body is horizontally arranged, and the edge groove-shaped body is obliquely arranged outwards.
9. A composite floor according to claim 1, characterised in that: the surface of the buffer body is provided with an embossing pattern.
10. A process for producing a composite floor according to any one of claims 1 to 9, comprising the steps of:
s1: preheating a support body made of a metal material, and conveying the support body into a processing flow channel of a mold through a tractor;
s2: the support body reaches a first processing section of the processing flow channel, and hot melt adhesive is extruded on the upper surface of the support body through a first extruder to form an adhesive layer, so that a first coating base material is obtained;
s3: the first coated substrate prepared in the step S2 reaches the second processing section of the processing flow channel, and the thermoplastic foam material is extruded on the upper surface of the first coated substrate by the second extruder to form the buffer body main body, so as to obtain a second coated substrate;
s4: the second coated substrate prepared in the step S3 reaches a third processing section of the processing flow channel, and a thermoplastic plastic with shore hardness of more than 65HD is coated on the upper surface of the second coated substrate through a third extruder to form a hard surface layer, so as to obtain a rectangular plate;
s5: the prototype plate manufactured in the step S4 is transported out of the die, and the composite floor is obtained after shaping and embossing treatment;
the upper runner wall of the first processing section corresponding to the upper surface of the support body is provided with a plurality of protruding pieces, and each protruding piece corresponds to one clamping groove; when the supporting body reaches the first processing section, the protruding part is embedded into the clamping groove, a distance is reserved between the outer contour of the protruding part and the groove wall of the clamping groove, and an adhesive layer filling area is formed.
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