CN115027117A

CN115027117A - Reinforced wood texture floor, preparation method thereof and co-extrusion die

Info

Publication number: CN115027117A
Application number: CN202210537711.7A
Authority: CN
Inventors: 唐道远
Original assignee: Anhui Sentai Wpc Technology Floor Co ltd
Current assignee: Anhui Sentai Wpc Technology Floor Co ltd
Priority date: 2022-05-18
Filing date: 2022-05-18
Publication date: 2022-09-09

Abstract

The present invention relates to a reinforced wood grain floor. Belonging to the technical field of co-extrusion foaming plates. A reinforced wood-grain floor includes a foam core having a shell formed of a first color resin and an attachment distributed on a surface of the shell formed of a second color resin; the shell is formed by integrally connecting a plurality of exposed units and sunken units which are arranged at intervals, the attachment body consists of a plurality of attachment body units, and the attachment body units are arranged in the sunken units; the foam core also comprises a hard foam core body filled in the shell and two layered reinforcing bodies respectively arranged between the upper surface and the lower surface of the hard foam core body and the shell. The invention further improves the compressive strength of the floor by arranging the layered reinforcement in the foam core, obviously improves the elastic modulus of the composite floor, can increase the span when laying the floor, reduces the laying cost and improves the laying efficiency.

Description

Reinforced wood texture floor, preparation method thereof and co-extrusion die

Technical Field

The invention relates to a foaming floor, in particular to a reinforced wood texture floor. Belonging to the technical field of co-extrusion foaming plates.

Background

The traditional wood-like floor is generally a composite floor. The wood-grain-free wear-resistant floor is composed of a density board base material, wood-grain decorative paper, a wear-resistant layer and a balance layer at the bottom. However, as the density board substrate is easy to mildew and rot and has fire hazard, the field needs a mildew-proof and flame-retardant floor. In this case, PVC foam flooring becomes an option. However, the shape and appearance of the PVC foamed floor do not meet the traditional use requirements of people, so that the added value of the PVC foamed floor is low, and the PVC foamed floor is difficult to use in large-area markets.

The Chinese patent application with the publication number of CN102294812A discloses a polystyrene wood-like section, which solves the problem of appearance defects of a plastic floor to a certain extent. The surface layer material and the core layer material are respectively put into an auxiliary extruder and a main extruder and are co-extruded to a die, so that the surface layer material is coated on the core layer material. The surface layer material is high impact polystyrene and contains flow pattern color master batch which has good compatibility with the high impact polystyrene but different fluidity and dispersibility, and the core layer material is a polystyrene micro-foaming plate. The surface of the co-extruded profile is embossed to produce a three-dimensional or other effect. The method adopts color master batches with different substrate colors to respectively prepare a base color master batch and a flow line master batch, wherein the base color master batch has good fluidity and is dispersed in a styrene material to form a base color in the processing process; the flow pattern color master batch has lower melt index and poorer dispersibility, can not be uniformly dispersed in the processing process, and forms wood grains or other patterns along with the extrusion of materials. The problems of mutual fusion and color cross of the base color and the flow pattern at the adjacent parts are easy to occur, the wood-like texture of the co-extrusion floor is greatly different from the wood texture, and the co-extrusion floor is generally used

The user can easily distinguish the above-mentioned floor from the solid wood floor in appearance.

Chinese patent No. CN10670839B discloses a foamed floor with wood grain. The floor is manufactured by co-extruding two color resin layers and then embossing and polishing the two color resin layers to form the wood texture floor with high simulation degree. At present, the floor is well appreciated by the users, and has great market prospect. However, the compressive strength and the elastic modulus of the floor need to be further improved so as to better meet the new requirements of the future market.

Disclosure of Invention

The present invention is to solve the above technical problems and to provide a reinforced wood grain floor. The floor provided by the invention has the advantages of vivid wood grain, light weight, high compressive strength and large elastic modulus.

The technical scheme for solving the problems is as follows:

a reinforced wood-grain floor comprising a foam core having a shell formed of a first color resin and an attachment distributed on a surface of the shell formed of a second color resin; the shell is formed by integrally connecting a plurality of exposed units and sunken units which are arranged at intervals, the attachment body consists of a plurality of attachment body units, and the attachment body units are arranged in the sunken units; the foam core also comprises a hard foam core body filled in the shell and two layered reinforcing bodies respectively arranged between the upper surface and the lower surface of the hard foam core body and the shell.

In the technical scheme of the invention, the appearance of the wood grains of the floor is formed by a plurality of exposed units and a plurality of attachment units which are arranged alternately.

Wood grain, which is usually represented by a large number of different cell types arranged in a certain order; on a microscopic level, the separation between different cell types is obvious; macroscopically, they are tightly combined and connected into a whole.

The present invention is somewhat analogous in some respects to the principles of wood grain formation. Firstly, the exposed unit and the attachment unit are not formed by the same raw material through the same process in the product structure design, and are usually of the same color system and have certain color difference, so that the separation interface between the exposed unit and the attachment unit is obvious, the color is clear, and the exposed unit and the attachment unit are visually coordinated; meanwhile, since the two materials are the same in nature, the combination between the two is very tight, and the attachment unit is difficult to peel off from the floor surface. And the exposed units and the attachment units are arranged according to the rules of wood grains, so that the wood grain forming principle is met. Therefore, the color difference feeling of the close combination is matched with the textures of the respective shapes, so that the wood grain texture has extremely strong wood grain texture.

In the above technical solution, the exposed units and the attachment units are arranged according to the rules of wood grains, which is related to the manufacturing method of the floor. The method for manufacturing the floor will be described in detail in the following description.

And the reinforcing mode is obviously different from the fiber reinforcement in the prior art. Fiber reinforcement is generally used by mixing reinforcing fibers as additives with a matrix resin; this approach has serious drawbacks: 1. the process of mixing the reinforcing fibers into the matrix resin pollutes operation workshops, brings extreme discomfort to workers, and can also cause lung diseases seriously; 2. the reinforcing fiber is difficult to disperse in the matrix resin; 3. after the reinforcing fiber is mixed into the matrix resin, the extrusion is difficult, and equipment needs to be upgraded and modified; 4. the increased strength is limited. It follows that future technologies are unlikely to evolve towards fibre reinforcement. In the above technical solution of the present invention, the reinforcing member is reinforced by two layered reinforcing members respectively disposed between the upper and lower surfaces of the rigid foam core and the shell.

Preferably, the layered reinforcement is a glass fiber mesh cloth or a glass fiber ribbon impregnated with a thermosetting resin.

In the prior art, continuous glass fibers and glass fiber meshes made of continuous glass fibers have become popular. The optional impregnation of a thermosetting resin to form the layered reinforcement is easily done and therefore will not be elaborated upon here. The difficulty of the invention is not how to make the layered reinforcement, but how to implant the layered reinforcement into the floor according to a certain rule to embody the supporting capability and the reinforcing capability. The method of embedding the layered reinforcement into the floor relates to a method of manufacturing the floor, and will be described in detail in the following description.

Preferably, in the above technical solution, the rigid foam core is made of foamed polyolefin, and the shell and the attachment are made of polyolefin;

or the hard foam core body is made of foamed polyolefin, the shell body is made of polyolefin modified by unsaturated carboxylic acid, and the attachment body is made of ASA.

The foamed polyolefin material is a material which is integrally formed by mixing and melting polyolefin serving as matrix resin (added with a foaming agent or prepared by a physical foaming process without adding the foaming agent) and plant fiber powder or stone powder serving as a filler with a processing aid or a functional aid.

The unsaturated carboxylic acid graft modified polyethylene material is an integrally formed material formed by uniformly mixing and melting unsaturated carboxylic acid graft modified polyethylene serving as matrix resin (such as maleic anhydride graft modified polyethylene) and plant fiber powder or stone powder serving as a filler and a processing aid or a functional aid.

The ASA material is prepared by taking ASA resin as matrix resin, taking plant fiber powder or stone powder as filler, mixing with processing aids or functional aids, uniformly mixing and melting to form an integrally formed material.

Based on the prior art, the ASA material has remarkable advantages compared with other materials: fire resistance, weather resistance and high temperature resistance; therefore, ASA materials are often used as surface coverings for outdoor floors. At the same time, the cost of ASA is significantly higher than that of PE or PVC, and if the shell is made into ASA, the cost of the product is significantly increased, and the market competitiveness of the product is lost.

Therefore, it is preferable to form the housing from a relatively inexpensive resin. Typically, PVC or PE/PP will be chosen. When PVC is selected, the compatibility of PVC and ASA is better, and the prepared product is not easy to crack. However, PVC is not good in environmental protection, and customers in some areas have strong conflict emotion to PVC, and PE/PP is the optimal choice. But PE/PP is a non-polar material and has poor compatibility with ASA; therefore, two solutions can be adopted: 1, improving the polarity of PE/PP, such as preparing a shell by grafting and modifying polyolefin with unsaturated carboxylic acid, and arranging an attachment on the shell, so that an outdoor floor with good weather resistance and wood grain attachment strength can be obtained; 2, the adhesion body is formed by polyolefin resin with a second color without ASA, and weather-resistant additives are used for strengthening the weather resistance of the shell and the adhesion body, so that the obtained outdoor floor wood grain has better adhesion strength, meets the requirements even though the weather resistance is slightly poor, has an advantage in price and also has good market prospect.

In the technical scheme of the invention, the floor is enhanced besides the vivid wood texture on the surface of the floor. And the reinforcing mode is obviously different from the fiber reinforcement in the prior art. Fiber reinforcement is generally used by mixing reinforcing fibers as additives with a matrix resin; this approach has serious drawbacks: 1. the process of mixing the reinforcing fibers into the matrix resin pollutes operation workshops, brings extreme discomfort to workers, and can also cause lung diseases seriously; 2. the reinforcing fiber is difficult to disperse in the matrix resin; 3. after the reinforced fiber is mixed into the matrix resin, the extrusion is difficult, and equipment needs to be upgraded and modified; 4. the increased strength is limited. It follows that future technologies are unlikely to evolve towards fibre reinforcement. In the above technical solution of the present invention, the reinforcing member is reinforced by two layered reinforcing members respectively disposed between the upper and lower surfaces of the rigid foam core and the shell.

In the prior art, continuous glass fibers and glass fiber meshes made of continuous glass fibers have become popular. It is also easy to impregnate it with a thermosetting resin to form a layered reinforcement, and therefore, the present invention is not developed in detail. The difficulty of the invention is not how to make the layered reinforcement, but lies in: how to implant the layered reinforcement body into the floor according to a certain rule to embody the supporting capability and the reinforcing capability. The method of embedding the layered reinforcement into the floor relates to a method of manufacturing the floor, and will be described in detail in the following description.

Another object of the present invention is to provide a method for manufacturing the above floor.

A method of making a reinforced wood grain floor comprising the steps of:

1) extruding matrix resin into a main runner of the mold through a main extruder to form a pressure maintaining core body;

2) feeding the layered reinforcement into a reinforcement channel of a mold;

3) feeding the first color resin into a first co-extrusion flow channel of a co-extrusion die through a first auxiliary extruder; feeding the second color resin into a second co-extrusion flow channel of the co-extrusion die through a second auxiliary extruder; then, co-extruding the first color resin and the second color resin from a composite section formed by the first co-extrusion flow channel and the second co-extrusion flow channel after being converged to form a shell formed by the first color resin and provided with a double surface layer with the surface covered by the second color resin;

4) extruding the pressure maintaining core, the layered reinforcement and the shell with double surface layers from respective independent runners to form a die blank; meanwhile, the mold blank is introduced into a shaping mold, a pressure maintaining core body is foamed in a shell constrained by the inner wall of the shaping mold in the shaping mold, the shell is filled, and meanwhile, the mold blank is compounded, cooled and shaped in the shaping mold to obtain a substrate;

5) performing a heat treatment on the substrate to adjust the substrate to a proper embossing state; the suitable embossing state is specifically: the surface temperature of the substrate is higher than the internal temperature, and the surface hardness of the shell and the second color resin layer is reduced relative to the respective cold state;

6) when the substrate is in a proper embossing state, embossing by an embossing roller to press partial area of the second color resin layer below the surface of the shell so that the shell and the second color resin layer jointly present a wood texture former state;

7) and through the polishing treatment, the second color resin which is not pressed below the surface of the shell is integrally polished, so that the corresponding area is exposed out of the shell, the floor surface presents the appearance that a plurality of exposed units and a plurality of attachment units are arranged alternately, and the previous state of the wood texture is converted into the wood texture.

The question of how to implant the layered reinforcement; this is difficult for those skilled in the art because it is generally understood that fusing the layered reinforcement to the foam core requires the reinforcing material channels to be in communication with the primary flow channels so that the glass fiber reinforced layers are fused into the foam layer. The problem that can be done 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 can be reversely released along the reinforcing material channel, the material in the main flow channel is naturally extruded into the reinforcing material channel, and even further foaming can be carried out, so that the reinforcing material channel is blocked, the layered reinforcing body is difficult to 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, because the pressure is released in advance, partial area foams in advance, and the quality of the foaming core is difficult to control.

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, the co-extrusion flow channel and the main flow channel are independent respectively and are converged at a port of the mold discharging plate; 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. the concept of coating the molded foaming core by the shell material in the past is abandoned; 3. the idea of using a prefabricated shell, filling the formed shell with a foam core to be foamed, and inserting said layered reinforcement during the filling process. In the invention, the filling is realized by automatic foaming and expansion of the pressure maintaining core body after the core body comes out from the main flow channel for pressure maintaining instead of continuously conveying the filling material to the inside of the shell; therefore, after the die blank is extruded from the die, the die blank needs to enter the stock mould immediately, the shell is restrained by the stock mould, the pressure maintaining core body is foamed in the shell restrained by the inner wall of the stock mould, and the shell is filled. Meanwhile, the shaping mold can be placed in a water tank to improve the cooling and shaping effects of the shaping mold.

Preferably, in the step 5), a tunnel oven is adopted to heat the surface of the substrate during reheating treatment, the temperature in the oven is controlled to be 150-250 ℃, and the time for passing the substrate is controlled to be 3-20 s.

Preferably, in the above-described aspect, in the step 6), when the embossing process is performed by using an embossing roller, the embossing roller is a cold roller.

Preferably, in step 7), a sander is used for sanding.

It is a further object of the present invention to provide a co-extrusion die for making the above-described flooring.

The co-extrusion mold is provided with a main runner, a reinforcing material channel and a co-extrusion runner; the main runner, the reinforcing material channel and the co-extrusion runner are independent in the mold;

the co-extrusion flow channel comprises a first co-extrusion flow channel and a second co-extrusion flow channel, and the first co-extrusion flow channel and the second co-extrusion flow channel are connected in a junction mode to form a composite section;

the reinforcing material channel comprises a first channel and a second channel which are distributed on two sides of the main channel, the first channel is provided with a first discharge port in a straight shape, and the second channel is provided with a second discharge port in a straight shape;

the discharge port of the co-extrusion runner is of a rectangular ring structure and is sleeved on the periphery of the main runner discharge port, the first discharge port is arranged between the upper frame of the main runner discharge port and the upper frame of the co-extrusion runner outlet, and the second discharge port is arranged between the lower frame of the main runner discharge port and the lower frame of the co-extrusion runner outlet.

Preferably, 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 becomes smaller along the material feeding direction until the included angle tends to zero.

As the optimization of the technical scheme, the co-extrusion die is formed by butting a plurality of die plates including a die feeding plate, a plurality of runner forming plates and a die discharging plate;

the first co-extrusion runner comprises a feeding section, a casting section and a forming section which are communicated with each other;

the feeding section is specifically two branch channels which are arranged on the inner end surfaces of the third flow channel forming plate and the second flow channel forming plate;

the casting section is specifically two mutually communicated inclined-plane-shaped channels which are arranged on the outer end face of the second flow channel forming plate;

the molding section is arranged on a first flow passage forming plate of the mold;

the branch channel is butted with the inclined plane-shaped channel, and the inclined plane-shaped channel is butted with the molding section;

the first co-extrusion flow channel and the second co-extrusion flow channel are connected at the forming section in a junction mode to form the composite section;

the composite section is arranged on the die discharging plate;

the inner end surface of the mold discharging plate is butted with the outer end surface of the first flow channel forming plate, the inner end surface of the first flow channel forming plate is butted with the outer end surface of the second flow channel forming plate, and the inner end surface of the second flow channel forming plate is butted with the outer end surface of the third flow channel forming plate; the rectangular annular structure of the cross section of the molding section gradually shrinks along the discharging direction until a discharging port of the co-extrusion flow channel is formed.

The technical scheme of the invention provides a detailed preparation method. The present invention is mainly achieved by embossing with an embossing roller having wood grains, with respect to the problem of how to form wood grains on the surface of the floor. Since the first color resin layer and the second color resin layer are embossed after the reheating, the wood grain can be engraved by the embossing; meanwhile, the first color resin layer and the second color resin layer are usually formed by using thermoplastic resin as matrix resin, so that the printed wood texture can be retained, and the problem of fading the texture due to resilience can be avoided.

Compared with the mold for pre-forming a single-layer color resin shell in the prior art, the mold provided by the invention has the advantages that the two colors of resin layers are obviously separated and are tightly combined, and the mold has remarkable progress significance. It is extremely difficult for those skilled in the art to achieve both a distinct color separation and a tight bond.

Wood-grain floors and reinforced floors exist in the prior art; but not reinforced wood grain floors. This is because the reinforced wood grain flooring is simple in structural design but very difficult to manufacture.

Based on the prior art, firstly preparing a foaming core with a shell according to a reinforced floor; then through another mould crowded a colour resin layer altogether, through the embossing and polish at last can. Such a method seems to be effective, but the resulting flooring presents several serious problems: after long-term use, the attachment for creating the wood grain effect is prone to cracking, i.e., the attachment warps and even detaches from the substrate.

The invention abandons the concept and does not co-extrude a resin layer on the original shell; but the original single-layer shell is changed into a two-layer shell structure. The two-layer shell structure is a shell of which at least the upper surface is covered with a resin layer of another color. The two layers are divided into channels during manufacturing, but are finally extruded from a composite port, so that the obtained shell with the two-layer structure has the characteristics of obvious color separation and tight combination.

Specifically, through the special design of the co-extrusion flow channel, the first co-extrusion flow channel and the second co-extrusion flow channel are connected in a junction mode to form a composite section. After the two co-extrusion flow channels converge, the overall co-extrusion flow channel still keeps the state of continuously reducing the caliber until the shell coated with the other layer of color resin layer is extruded from the outlet of the die; furthermore, the invention controls the shell layer formed by the first color resin and the second color resin layer to be slightly cured but not completely cured, and the shell layer has high curing degree and the second color resin layer has low curing degree; in this state, the two color resin layers are converged and collectively extruded in a gradually narrowing passage, and finally a housing covered with the other color resin layer is formed.

In conclusion, the invention has the following beneficial effects:

1. according to the invention, through the two color resin layers, the operations of embossing and polishing are matched, so that vivid wood textures are manufactured on the surface of the floor, the method accords with the wood grain forming principle, and the effect of being false and spurious is achieved;

2. according to the invention, the layered reinforcement is arranged in the foam core, so that the compressive strength of the floor is further improved, the elastic 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 40MPa at 75 ℃; moreover, the thermal shrinkage rate of the invention is only-0.16%, which is far less than or equal to-1.4% of the detection requirement; therefore, the invention has excellent bending resistance effect under high temperature environment;

3. the production method provided by the invention can endow the floor with higher compressive strength, higher bending failure load and higher bending elastic modulus;

4. according to the invention, through the specially designed die, the two color resin layers of the manufactured shell are obviously separated in color and are tightly combined.

Drawings

FIG. 1 is a schematic diagram of the product structure of the present invention;

FIG. 2 is an enlarged view of a portion of FIG. 1;

FIG. 3 is a schematic view of a mold structure;

FIG. 4 is a schematic view of the outer end face of a fourth flow channel forming plate of the co-extrusion die;

FIG. 5 is a schematic view of the outer end face of the third flow channel forming plate of the co-extrusion die;

FIG. 6 is a schematic view of the outer end face of a second flow channel forming plate of the present invention;

FIG. 7 is a schematic view of the outer end face of the first flow channel forming plate of the present invention;

FIG. 8 is a schematic view of a second mold of the present invention;

in the figure, 1100-attachment, 2000-foam core, 2100-shell, 2101-exposed unit, 2102-depressed unit, 2300-rigid foam core, 2200-layered reinforcement; 1101-an adherent unit;

10-a main runner, 20-a reinforcing material channel and 30-a co-extrusion runner; 50-feed inlet, 60-harness cord component;

21-a first channel, 22-a second channel, 31-a first co-extrusion flow channel, 32-a second co-extrusion flow channel;

100-a mold discharge plate, 200-a first flow channel forming plate, 300-a second flow channel forming plate, 400-a third flow channel forming plate;

201-input section, 202-output section, 211-first discharge port, 221-second discharge port;

301-feeding section, 302-casting section, 303-forming section, 3011-branch channel and 3021-inclined plane channel.

Detailed Description

The invention is further explained below with reference to the drawings.

The present embodiments are to be considered in all respects as illustrative and not restrictive. Any changes that may be made by one skilled in the art after reading the description of the invention herein will be covered by the patent laws within the scope of the appended claims.

Example one

As shown in fig. 1, a reinforced wood-grain floor includes a foam core 2000, the foam core 2000 having a housing 2100, and an attachment 1100 on a surface of the housing 2100.

The housing 2100 is formed of a first color resin; the attached body 1100 is formed of a second color resin.

As shown in fig. 2, the housing 2100 is formed by integrally connecting a plurality of exposed units 2101 arranged alternately with a sunken unit 2102, the attachment 1100 is formed by a plurality of attachment units 1101, and the attachment units 1101 are disposed in the sunken units 2102; the foam core 2000 further includes a rigid foam core 2300 filled in the housing 2100, and two layered reinforcements 2200 respectively provided between the upper and lower surfaces of the rigid foam core 2300 and the housing 2100.

In this embodiment, the first color resin and the second color resin are both made of PE; the first color resin and the second color resin are the same composition except for the colors. The rigid foam core 2300 is made of highly foamed PE, and generally has a density of 0.5-0.8 g/cm for thin-wall cultivation, in this embodiment, 0.7g/cm for thin-wall cultivation. The layered reinforcement 2200 is a fiberglass mesh impregnated with thermosetting resin. The fiberglass scrim forms a rigid sheet after being covered with ABS. The layered reinforcement 2 is made from a second mold.

As shown in fig. 8, one end of the main runner is a die opening of the mold, and the die opening is flat; the other end is sealed, and a feed inlet 50 of the die is arranged at the side part of the die; one end of the seal of the mold is provided with a harness cord part 60 which allows the glass fiber mesh cloth to be introduced and limits the molten resin in the main runner to flow out. The harness cord component is provided with two ends, one end is a tip end and is arranged in the die cavity of the second die, and the other end is a tail end and is arranged on an end cover at the sealed end of the second die; and a channel allowing the mesh cloth to enter is formed between the tip end and the tail end. The preparation method comprises the following steps:

s1, introducing the mesh cloth made of glass silk yarns into a second mould from one end of a seal of the second mould, and pulling out the mesh cloth from one end of a die orifice of the second mould to keep the mesh cloth in a stretched straight state;

s2, melting and extruding the ABS resin by an extruder, and entering a main runner of the second die from a material inlet arranged on the side part of the second die; enabling the molten ABS resin to meet the grid cloth in a stretched state in the main flow channel; then, the ABS resin and the gridding cloth are extruded out from one end of the die orifice of the second die, and the layered reinforcement 2 is prepared.

The preparation method of the floor comprises the following steps:

1) adding matrix resin into a main extruder, extruding the matrix resin into a main runner 10 of a mold by the main extruder, and extruding the matrix resin from the main runner 10 to form a pressure maintaining core body;

2) feeding two layered reinforcement members 2200 from the first channel 21 and the second channel 22, respectively;

3) feeding the first color resin from a first co-extrusion flow channel 31 of the co-extrusion die through a first auxiliary extruder, and extruding the first color resin from an outlet of the first co-extrusion flow channel 31 to form a first color resin layer; feeding a second color resin from a second co-extrusion flow channel 32 of the co-extrusion die through a second auxiliary extruder, and extruding the second color resin from an outlet of the second co-extrusion flow channel 32 to form a second color resin layer covering the first color resin layer; then, the first color resin layer and the second color resin layer are jointly extruded from a composite outlet formed after the first co-extrusion flow channel 31 and the second co-extrusion flow channel 32 are jointed, and the shell 2100 with the second color resin layer covered on the outer surface is obtained;

4) extruding the pressure maintaining core, the layered reinforcement 2200 and the shell 2100 with the outer surface covered with the second color resin layer from the respective independent flow channels to form a mold blank; meanwhile, the mold blank is introduced into a shaping mold, the pressure maintaining core body is foamed in the shell 2100 constrained by the inner wall of the shaping mold in the shaping mold, the shell 2100 is filled, and the mold blank is compounded and shaped in the shaping mold to form a foamed core 2000 with the outer surface covered with a resin layer with a second color; the die blank comprises a pressure maintaining core body, a layered reinforcement 2200 and a shell 2100 from inside to outside in sequence;

5) cooling the foam core 2000 covered with the second color resin layer on the outer surface to obtain a substrate;

6) performing a heat treatment on the substrate to adjust the substrate to a proper embossing state; the suitable embossing state is specifically: the surface temperature of the substrate is higher than the internal temperature and the surface hardness of the housing 2100 and the second color resin layer is reduced relative to the respective cold state; during reheating treatment, a tunnel type oven is adopted to heat the surface of the intermediate product, the temperature in the oven is controlled at 200 ℃, and the time for passing the substrate is controlled at 15 s;

7) when the substrate is in a proper embossing state, deep embossing is carried out through an embossing roller, and partial areas of the second color resin layer are pressed below the surface of the shell 2100, so that the shell 2100 and the second color resin layer jointly present a wood texture former state; when the embossing roller is used for deep embossing, the embossing roller is a cold roller;

8) and performing a sanding process by using a sanding machine, and integrally sanding off the second color resin which is not pressed below the surface of the housing 2100, so that the corresponding area is exposed out of the housing 2100, and the floor surface presents the appearance that the plurality of exposed units 2101 and the plurality of attachment units 1101 are arranged alternately, so that the previous state of the wood texture is converted into the wood texture.

The production system for preparing the floor comprises a main extruder, a first auxiliary extruder, a second auxiliary extruder, a co-extrusion die and a shaping die.

As shown in FIGS. 3-7; the co-extrusion die is formed by butting a plurality of die plates including a die feeding plate, a plurality of flow channel forming plates 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; the main runner 10, the reinforcing material channel 20 and the co-extrusion runner 30 are independent from each other in the mold;

the co-extrusion flow channel 30 comprises a first co-extrusion flow channel 31 and a second co-extrusion flow channel 32, and the first co-extrusion flow channel 31 and the second co-extrusion flow channel 32 are connected in a junction manner to form a composite section;

the reinforcing material channel 20 comprises a first channel 21 and a second channel 22 distributed at two sides of the main channel 10, the first channel 21 is provided with a first discharge port 211 in a straight shape, and the second channel 22 is provided with a second discharge port 221 in a straight shape;

the discharge port of the co-extrusion flow channel is of a rectangular ring structure and is sleeved on the periphery of the main flow channel discharge port 11, the first discharge port 211 is arranged between the upper frame of the main flow channel discharge port and the upper frame of the co-extrusion flow channel outlet, and the second discharge port 221 is arranged between the lower frame of the main flow channel discharge port and the lower frame of the co-extrusion flow channel outlet.

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 angle between the input segment 201 and the main channel 10 gradually decreases along the material feeding direction until it approaches zero.

As shown in fig. 3 and 6, the first coextrusion runner 30 includes a feeding section 301, a casting section 302 and a forming section 303 which are communicated with each other;

the feeding section 301 is specifically two branch channels 3011 formed on the inner end surfaces of the third flow channel forming plate 400 and the second flow channel forming plate 300;

as shown in FIG. 4, the casting section 302 is specifically a two mutually communicating slant-shaped passages 3021 opened in the outer end face of the second flow passage forming plate 300;

the molding section 303 is arranged on the first flow passage forming plate 200 of the mold;

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 first co-extrusion flow channel 31 and the second co-extrusion flow channel 32 are connected at the forming section 303 to form the composite section;

the composite section is arranged on the die discharging plate 100;

an inner end surface of the mold discharge plate 100 is butted against an outer end surface of the first flow channel formation plate 200, an inner end surface of the first flow channel formation plate 200 is butted against an outer end surface of the second flow channel formation plate 300, and an inner end surface of the second flow channel formation plate 300 is butted against an outer end surface of the third flow channel formation plate 400; the rectangular annular structure of the cross section of the molding section 303 gradually shrinks along the discharging direction until a discharging port of the co-extrusion flow channel is formed.

Specifically, with reference to fig. 4 and 5, it can be seen that the specific structure of the reinforcing material channel 20, the input section 201 of which is formed by abutting the adjacent inner and outer end surfaces of two adjacent runner plates, is not formed by digging on one runner plate; that is, when the mold is disassembled into mold plates, the reinforcement material channel 20 is virtually unobservable, and only the end faces of two of the mold plates, both having two arcuate faces, can be seen to be uneven; when assembled, the two arcuate faces of the two mold plates are butted to form the input section 201 of FIG. 3. This has the advantage of enabling a large open channel to be created to facilitate placement of the layered reinforcement 2200; meanwhile, the channel is convenient to clean. Whether the channel can be cleaned conveniently is actually very critical, and the relation is whether the mould can be maintained without stopping the machine during daily production. On the other hand, fig. 4 also gives technical information of the main channel 10. Unlike the prior art, the main channel of the prior art is a main channel that passes through the mold from front to back, and the material for forming the rigid foam core 2300 is introduced into the main channel. In the present invention, as can be seen from fig. 3 and 4, a hollow core rod is arranged in the main channel, and the main channel 10 is opened in the hollow core rod; the space between the hollow core rod and the main channel is the reinforcing material channel 20; it should be noted that the mold plate represented by fig. 4 alone, i.e., the fourth flow channel forming plate in the present embodiment, cannot form the reinforcing material passage 20 alone, and the reference numeral 20 is used to indicate the reinforcing material passage, which indicates that the reinforcing material passage 20 is formed at the portion after the mold plate is assembled to form the mold. And figure 4 gives further technical information. As shown in fig. 4, the main channel 10 provided in the hollow core rod of the present invention is not a flat channel, but a collection of several branch channels; the plurality of branch passages are formed by arranging partition plates. The foaming device has the advantages that the foaming materials are controlled to be uniformly distributed in the main runner, the hard reinforcing core is prevented from being foamed unevenly, and hollowing at two sides of the plate in the shell is further avoided, so that the product quality is improved. The left half of fig. 4 is a side view of the corresponding mold runner plate, and the right half is a front view of the mold runner plate; as can be seen in the side view of fig. 4, the upper and lower surfaces of the outer contour of the primary flow channel 10 are arc-shaped faces; the arc-shaped surface is further represented by a plurality of arc-shaped lines in the front view of fig. 4, otherwise it looks like a plane in the perspective of the front view, which may affect the understanding of the structure by those skilled in the art. That is, in the front view of fig. 4, the curved lines have no substantial meaning, and only represent that the region is a curved surface.

Fig. 5 shows the passage of the housing material, i.e. the first coextrusion channel 31; but only a part of the first co-extrusion channel 31, i.e. the said feed section 301. The left half of fig. 5 is a side view of the corresponding mold runner plate, and the right half is a front view of the mold runner plate; as can be seen in the side view of fig. 5, the outer profile on one face of the die runner plate is two arcuate faces; in practice, these two curved surfaces are paired with the curved surfaces shown in fig. 4, i.e. together form the feed section 201 of the reinforcing material channel 20. It should be noted that the mold plate represented by fig. 5 alone, i.e., the fourth flow channel forming plate in the present embodiment, cannot form the reinforcing material passage 20 alone, and the reference numeral 20 is used to indicate the reinforcing material passage, which indicates that the reinforcing material passage 20 is formed at the portion after the mold plate is assembled to form the mold. In fig. 4, a plurality of arc-shaped dashed lines are used for representing that the corresponding area is an arc-shaped surface without other essential meanings. Similarly, in the front view of fig. 5, the corresponding region is also indicated as an arc surface by a plurality of arc lines, but it is further noted that the arc surface is on the front surface in fig. 4; whereas the arc of fig. 5 appears on the back and fig. 5 is a front view, the arc is not actually visible, but is not shown to facilitate understanding of the technique of the invention, and is further indicated by dashed lines in fig. 5. That is, the several arcuate lines in FIG. 5 represent the presence of an arcuate surface on the back side of the mold plate. It can be seen that when the two arcuate surfaces of fig. 4 and 5 are brought into abutment, the inlet section 201 of the channel 20 of reinforcement material is formed.

Example two

This embodiment is substantially the same as the first embodiment, except that: in the first embodiment, the first color resin and the second color resin are both made of PE; in this embodiment, the first color resin is made of maleic anhydride graft modified PE, and the second color resin is made of ASA.

Comparative example 1

According to patent document CN 110670839B, a foamed floor having wood grain was produced.

The products of example one, example two and comparative example one were tested in accordance with the disclosure of BS EN 15534-1-2014+ A1-2017 for flexural breaking load, flexural strength, surface hardness and surface wear resistance, and the results are shown in the following table.

Claims

1. A reinforced wood grain floor comprising: the foam core comprises a foam core (2000) with a shell (2100) and attachment bodies (1100) distributed on the surface of the shell (2100), wherein the shell (2100) is formed by a first color resin, and the attachment bodies (1100) are formed by a second color resin; the shell (2100) is formed by integrally connecting a plurality of exposed units (2101) and sunken units (2102) which are arranged at intervals, the attachment body (1100) is composed of a plurality of attachment body units (1101), and the attachment body units (1101) are arranged in the sunken units (2102); the foam core (2000) further comprises a rigid foam core body (2300) filled in the shell body (2100) and two layered reinforcing bodies (2200) respectively arranged between the upper and lower surfaces of the rigid foam core body (2300) and the shell body (2100).

2. A reinforced wood grain floor as recited in claim 1, wherein: the layered reinforcement (2200) is glass fiber mesh cloth or glass fiber ribbon impregnated with thermosetting resin.

3. The reinforced wood-grain floor as recited in claim 1, wherein: the hard foaming core body (2300) is made of foamed polyolefin, and the shell body (2100) and the attachment body are made of polyolefin; or the hard foaming core body (2300) is made of foamed polyolefin, the shell body (2100) is made of polyolefin modified by unsaturated carboxylic acid, and the attachment body is made of ASA.

4. A method of making a reinforced wood-grain floor as recited in any one of claims 1 to 3, comprising the steps of:

1) extruding matrix resin into a main runner (10) of a mold through a main extruder to form a pressure maintaining core body;

2) feeding the layered reinforcement (2200) into a reinforcement channel of a mold;

3) feeding the first color resin into a first co-extrusion flow channel (31) of a co-extrusion die through a first auxiliary extruder; feeding the second color resin into a second co-extrusion flow channel (32) of the co-extrusion die through a second auxiliary extruder; then, co-extruding the first color resin and the second color resin from a composite section formed by the first co-extrusion flow channel (31) and the second co-extrusion flow channel (32) after being jointed to form a shell (2100) which is formed by the first color resin and is covered with a double-surface layer of the second color resin;

4) extruding the pressure maintaining core body, the layered reinforcing body (2200) and the shell (2100) with double surface layers from respective independent flow channels to form a die blank; meanwhile, the mould blank is led into a shaping mould, a pressure maintaining core body is foamed in a shell (2100) constrained by the inner wall of the shaping mould in the shaping mould, the shell (2100) is filled, and meanwhile, the mould blank is compounded, cooled and shaped in the shaping mould to obtain a substrate;

5) performing a heat treatment on the substrate to adjust the substrate to a proper embossing state; the suitable embossing state is specifically: the surface temperature of the substrate is higher than the internal temperature and the surface hardness of the housing (2100) and the second color resin layer is reduced relative to the respective cold state;

6) when the substrate is in a proper embossing state, embossing by an embossing roller to press partial area of the second color resin layer below the surface of the shell (2100), so that the shell (2100) and the second color resin layer jointly present a wood texture former state;

7) and integrally grinding the second color resin which is not pressed below the surface of the housing (2100) through a grinding process so that the corresponding area is exposed out of the housing (2100), so that the floor surface presents the appearance that a plurality of exposed units (2101) and a plurality of attachment units (1101) are arranged alternately, and the former state of the wood texture is converted into the wood texture.

5. The method of making a reinforced wood grain floor as recited in claim 4, wherein: in the step 5), during reheating treatment, a tunnel type oven is adopted to heat the surface of the substrate, the temperature in the oven is controlled to be 150-250 ℃, and the passing time of the substrate is controlled to be 3-20 s.

6. The method of making a reinforced wood-grain floor as recited in claim 4, wherein: and 6), when the embossing roller is used for embossing, the embossing roller is a cold roller.

7. The method of making a reinforced wood grain floor as recited in claim 4, wherein: and 7), polishing by using a sander.

8. Co-extrusion die for making a reinforced wood-grain floor as claimed in any one of claims 1 to 3, characterized in that:

the co-extrusion flow channel comprises a first co-extrusion flow channel (31) and a second co-extrusion flow channel (32), and the first co-extrusion flow channel and the second co-extrusion flow channel are connected in a junction mode to form a composite section;

the reinforcing material channel (20) comprises a first channel (21) and a second channel (22) which are distributed on two sides of the main channel (10), the first channel (21) is provided with a first discharge hole (211) in a straight shape, and the second channel (22) is provided with a second discharge hole (221) in a straight shape;

the discharge port of the co-extrusion runner is of a rectangular ring structure and is sleeved on the periphery of the main runner discharge port (11), the first discharge port (211) is arranged between the upper frame of the main runner discharge port and the upper frame of the co-extrusion runner outlet, and the second discharge port (221) is arranged between the lower frame of the main runner discharge port and the lower frame of the co-extrusion runner outlet.

9. A co-extrusion die as claimed in claim 8, wherein: 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 becomes smaller along the material feeding direction until the included angle tends to zero.

10. The method of making a reinforced wood-grain floor as recited in claim 7, wherein:

the co-extrusion die is formed by butting a plurality of die plates including a die feeding plate, a plurality of runner forming plates and a die discharging plate;

the first co-extrusion runner (30) comprises a feeding section (301), a casting section (302) and a forming section (303) which are communicated with each other;

the feeding section (301) is specifically two branch channels (3011) which are arranged on the inner end surfaces of the third flow channel forming plate (400) and the second flow channel forming plate (300);

the casting section (302) is specifically two communicated inclined plane-shaped channels (3021) which are arranged on the outer end surface of the second flow channel forming plate (300);

the molding section (303) is arranged on a first flow passage forming plate (200) of the mold;

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 first co-extrusion flow channel (31) and the second co-extrusion flow channel (32) are jointed at the forming section (303) to form the composite section;

the composite section is arranged on a die discharging plate (100);

the inner end surface of the mold discharging plate (100) is butted against the outer end surface of the first flow channel forming plate (200), the inner end surface of the first flow channel forming plate (200) is butted against the outer end surface of the second flow channel forming plate (300), and the inner end surface of the second flow channel forming plate (300) is butted against the outer end surface of the third flow channel forming plate (400); the rectangular annular structure of the cross section of the forming section (303) gradually shrinks along the discharging direction until a discharging port of the co-extrusion flow channel is formed.