CN115030437A - Novel molding floor - Google Patents

Novel molding floor Download PDF

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Publication number
CN115030437A
CN115030437A CN202210519305.8A CN202210519305A CN115030437A CN 115030437 A CN115030437 A CN 115030437A CN 202210519305 A CN202210519305 A CN 202210519305A CN 115030437 A CN115030437 A CN 115030437A
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CN
China
Prior art keywords
floor
core material
frame
base material
density
Prior art date
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Pending
Application number
CN202210519305.8A
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Chinese (zh)
Inventor
陈俊
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10957402 Canada Inc
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10957402 Canada Inc
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Publication date
Application filed by 10957402 Canada Inc filed Critical 10957402 Canada Inc
Priority to CN202210519305.8A priority Critical patent/CN115030437A/en
Priority to PCT/CN2022/102104 priority patent/WO2023216388A1/en
Priority to CA3233886A priority patent/CA3233886A1/en
Publication of CN115030437A publication Critical patent/CN115030437A/en
Pending legal-status Critical Current

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    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00Flooring
    • E04F15/02Flooring or floor layers composed of a number of similar elements
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00Flooring
    • E04F15/02Flooring or floor layers composed of a number of similar elements
    • E04F15/10Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials
    • E04F15/107Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials composed of several layers, e.g. sandwich panels
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00Flooring
    • E04F15/18Separately-laid insulating layers; Other additional insulating measures; Floating floors
    • E04F15/181Insulating layers integrally formed with the flooring or the flooring elements
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00Flooring
    • E04F15/18Separately-laid insulating layers; Other additional insulating measures; Floating floors
    • E04F15/20Separately-laid insulating layers; Other additional insulating measures; Floating floors for sound insulation
    • E04F15/203Separately-laid layers for sound insulation
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00Flooring
    • E04F15/22Resiliently-mounted floors, e.g. sprung floors
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00Flooring
    • E04F15/22Resiliently-mounted floors, e.g. sprung floors
    • E04F15/225Shock absorber members therefor

Abstract

The invention relates to the technical field of floors and discloses a novel molded floor which comprises a base material and a core material, wherein the base material is at least provided with a core material filling cavity, the core material is filled in the core material filling cavity, and a lock catch structure connected with an adjacent floor is circumferentially arranged on the side surface of the base material; the base material is made of a high-strength waterproof material, and the core material is made of a low-density foaming waterproof material; the novel molding floor provided by the invention solves the problems of high cost and high transportation cost of the existing floor material.

Description

Novel molding floor
Technical Field
The invention relates to the technical field of floors, in particular to a novel molded floor.
Background
Plastic flooring, particularly stone flooring, has become popular worldwide for the last decade, replacing laminate flooring due to its waterproof and formaldehyde-free properties. In 2021, the industry statistics all over the world shows that the sales volume of the plastic floor reaches more than 210 hundred million USDs (Universal Serial bus), and the sales volume of the plastic floor is expected to exceed 350 hundred million USDs (United states of America) in 2026, so that the plastic floor is a kind of floor which is developed and grows faster in the floor industry and has a tendency of replacing reinforced floors and partial ceramic tiles.
Plastic floorings, in particular SPC (stone plastic floorings), are distinguished above all by perfect water resistance, a high-strength structure, zero formaldehyde emission and good wear resistance. However, plastic flooring itself has some drawbacks and some of the common disadvantages of flooring, as listed below:
the main problems of the current plastic floor (including the stone plastic floor SPC) in the using process are as follows:
the surface scratch resistance is not ideal, and the scratch resistance of the same grade cannot be enhanced; the density is high, the weight is heavy, especially the stone plastic floor, the specific gravity reaches 2, thus the transportation cost is greatly improved; the thickness is thinner (4 mm-6mm is popular in the market), the main reason is that the cost of raw materials (plastics) is high, and compared with the 12mm reinforced floor commonly used in the market, the cost of SPC floor with the thickness of 1mm is 3 times of that of the reinforced floor with the same thickness; the relatively thin thickness of the stone plastic floor (SPC) has relatively large negative influence on the use performance in the aspects of comfort, noise prevention, heat insulation and the like; in addition, although the plastic floor/stone floor has perfect waterproof property, if water is generated indoors, the water penetrates under the floor, cannot be discharged, can breed mildew, bacteria and the like, and even can seriously affect the health of people, so the floor still needs to be replaced integrally; due to the thin thickness of the plastic/stone plastic floor, the spliced lock catch is small, so that the floor generates micro deformation due to environmental changes (especially temperature changes), and the tension of the lock catch is also a great challenge.
The structures of the existing plastic floor, such as LVT, PVC, SPC and the like are basically similar single-layer structures, and the structures are made of the same material from top to bottom and from inside to outside, so that the waterproof floor has the biggest problem of high material cost, very heavy weight and the specific gravity of 1.5-2 generally; or a double-layer structure, wherein the main structure is the floor, and a second layer is added below the floor for mute use; or a double-layer structure, the main structure is still the floor board itself, and the lower second layer structure is used as a structure for reducing the weight and increasing the thickness of the floor board, but the layer is provided with the lock catch, so that the density is required to be high enough to maintain the tensile strength of the lock catch, and the density is generally not lower than 800 KG. Due to the need to maintain the complete waterproof performance of the floor, although the density of the material is reduced, and partial transportation cost is saved, the reduction of the overall cost and the transportation cost of the floor is very limited; or a three-layer structure, the surface is a floor layer, the middle is a weight-reducing layer, and the bottom is a silencing pad. Such a structure is a combination of the two structures, and the base pad is generally relatively soft and cannot be used as a structural material.
Disclosure of Invention
It is an object of the present invention to provide a novel molded flooring that solves at least one of the above-mentioned problems of the prior art.
In order to achieve the purpose, the invention adopts the following technical scheme:
the novel molded floor comprises a base material and a core material, wherein the base material is at least provided with a core material filling cavity, the core material is filled in the core material filling cavity, a locking structure connected with an adjacent floor is circumferentially arranged on the side surface of the base material, and the locking structure is completely free from the influence of the core material; the base material is made of a high-strength waterproof material, and the core material is made of a low-density foaming waterproof material.
The technical scheme is to overcome the defects of the prior stone-plastic/plastic floor, the floor is fundamentally improved in structure, meanwhile, the core material is made of the low-density foaming waterproof material, so that the floor also keeps the perfect waterproof performance, in addition, the foaming material can have more excellent performances such as silence, heat insulation, elasticity and the like, particularly, compared with a commonly used 2-3mm base mat at present, the performance can be greatly improved, meanwhile, the stability of the base material is further improved by the core material, and the material of the core material can be selected according to the use environment and the purpose, so that the application environment of the floor is increased. Specifically, the floor structure is changed from a common plane structure to a base material with at least one core material filling cavity, and the base material is made of a high-strength material such as SPC (super cold press), so that the strength and the stability of the whole structure of the floor are ensured; the core material is filled in the core material filling cavity, and the core material is made of a low-density material, so that a high-thickness and low-cost floor product is possible. The design of combining the base material made of the high-strength material and the core material made of the low-density material has the structural advantage that the material cost and the weight of the stone-plastic floor are greatly reduced, and the stone-plastic floor with high thickness, such as the stone-plastic floor with the thickness of 12mm or more, cannot be produced due to the limitation of the technology and equipment for producing the stone-plastic floor at present.
In addition, as the core material is filled in the core material filling cavity, the upper end and the periphery of the core material are completely surrounded by the base material, namely, the base material can provide good protection for the core material, and the structure completely avoids the condition that the two-layer or multi-layer structure of the common floor causes delamination due to poor gluing quality.
In conclusion, the structural design of the floor board in the technical scheme reduces the use thickness of the high-strength material under the condition of ensuring enough strength and hardness in the use process of the floor board, so that the high-strength raw material is greatly saved, the cost of the raw material is reduced, and meanwhile, because the weight of the floor board is greatly reduced, the packing amount of floor board transportation is greatly improved under the condition of the same weight limit, and the transportation cost is further reduced. That is, the design can reduce the production cost of products and the weight under the condition of greatly increasing the thickness of the floor, thereby greatly reducing the transportation cost, the density of the core material is low, the waterproof floor which is thicker than the current market can be produced, and the cost is greatly reduced; the thickness is increased, and the performances of heat insulation, moisture insulation, sound insulation and the like of the floor can be greatly improved.
Compared with the common SPC floor, the cost of the whole material of the technical scheme is greatly reduced, and the laminated SPC floor can be compared favorably with a reinforced floor with the same thickness. The molded floor adopting the technical scheme has the advantages of high thickness, high performance, multifunction, low cost and water resistance, and cannot be achieved by the existing stone-plastic floor.
Specifically, this molding floor has the possibility of multiple extended function development, thereby can carry out the functional of special design increase floor through the material that the adjustment core chooseed for use or to the structure of core, for example the core adopts elastic material, thereby promote the comfort level that the floor foot was stepped on, perhaps the embedded ground heating coil of establishing of core, thereby can realize laying the laying of ground heating coil when laying the floor, saved and need lay the process of ground heating coil in the floor below alone, more save the construction process.
Furthermore, the upper surface of the base material is sequentially provided with a wear-resistant layer and a decorative layer, the wear-resistant layer is positioned on the upper surface of the decorative layer, and the decorative layer is directly printed on the surface of the base material.
The base material may have a plurality of layers of core materials embedded therein, and the number of layers, number, and material of the core materials may be specifically set according to the use environment and the demand, and is not particularly limited. Preferably, the core material is flat to ensure good contact and adhesion with the substrate and other surfaces.
In order to adapt to different application scenarios and use requirements, the material and/or thickness of each layer of core material can be different.
Because the core material is arranged in the base material, the density of the core material can be far lower than that of the base material, and meanwhile, the core material can provide enough supporting strength, and the material density of the core material can be adjusted and controlled according to the use environment. The core material can be made of materials with different properties, so that the floor with different requirements, such as hard floor, elastic floor or other required floor, can be produced according to the requirements of customers or environment, and meanwhile, the sufficient strength, hardness and toughness of the surface of the floor are ensured. In addition, according to the requirements of customers or use environments, the core material can be replaced by any material with proper density, so that the use range and the diversity of performance of the product are greatly improved.
The core material can also adopt a multi-layer structure, and materials with different thicknesses and different varieties can be used in each layer according to market requirements, so that the comfort level, the heat insulation performance, the sound insulation performance and the like of the product are improved, and the development of different series of products is facilitated.
For example, the core material can be selected from low-density foaming waterproof materials such as PVC, PP, PE, EVA, TPU, EPDM, rubber and the like. The low-density material provided by the technical scheme has the advantages that the density of the low-density material can be only up to the level of supporting the weight on the floor, such as walking of people and placement of furniture and household equipment; the choice of materials can be tailored to the context of use, such as a home, commercial, or industrial application context, and the like.
The substrate can also adopt an assembled waterproof structure, such as a small square frame structure, the small square frames are connected to form the length required by the substrate, the surface of the substrate is pasted with required materials, the required materials can be waterproof plastic materials, and can also be other materials, and the square frame (namely the core material filling cavity) is filled with the core material;
the base material can also adopt a completely separated spare part structure, the spare parts are firstly combined into a square frame, are sequentially connected, are combined into the required length and width of the base material, and then are pasted with the required material on the surface, such as a waterproof plastic material, and can also be other materials, and the square frame (namely the core material filling cavity) is filled with the core material.
Further, the density of the low-density foaming waterproof material is 100kg/m 3 -800kg/m 3 The density of the high-strength waterproof material is more than 800kg/m 3
In the technical scheme, the core material is in the base material, so that the density of the core material can be as low as 100kg/m 3 Thus, the overall cost and weight of the floor can be greatly reduced, and the transportation cost can be further reduced.
It should be noted that the substrate can be made of a material with high strength, high hardness, water resistance, sanitation, safety and certain toughness, such as a stone-plastic material (plastic + stone powder + additive), so as to ensure the strength and hardness of the surface, and is suitable for use in home and commercial environments.
Furthermore, the bottom of the core material positioned at the lowest part is provided with a groove, preferably, the lowest end of the core material can exceed the lower end of the base material by 2-4mm or more, and the requirements of the market and customers are met.
The bottom of the core material is provided with a groove, so that the lower end of the floor is of a hollow structure, and redundant water can be discharged in a shunting manner more easily and more quickly; in addition, a layer of air is kept between the ground and the floor, so that the heat insulation performance of the product is improved, the growth of mould is reduced, and the floor does not need to be replaced completely after the surface of the floor is cleaned, so that the use cost is greatly saved; the condition that the ground is soaked by a large amount of water is small, because the lowest end of the core material exceeds the lower end of the base material by 2-4mm, the floor is in cylindrical contact with the ground, and a sufficient gap is reserved between the back surface of the floor and the ground, so that water below the floor can be drained in a free flowing manner, mildew and bacteria are avoided, the cleanness and sanitation of the environment are kept, meanwhile, a new floor does not need to be replaced, and the loss caused by water damage is greatly saved; in addition, the lower end of the floor is of a hollow structure, the shock resistance of a product is improved, noise is reduced, a shock-absorbing/sound-insulating ground mat is not needed, the comfort degree of walking on the floor is improved, and meanwhile, due to the structural design of the grooves, materials are saved.
The depth of the grooves can be 1/2-3/4 of the thickness of the core material, the grooves are of a hemispherical structure, the floor board is guaranteed to have optimal resistance under the condition of gravity, and the part in contact with the ground is a columnar support body between the adjacent grooves.
Furthermore, the base material is internally provided with a grid-shaped reinforcing rib, and the core material filling cavity is divided into a plurality of cavities by the grid-shaped reinforcing rib.
In order to enhance the overall strength of the base material, it is necessary to have grid ribs formed on the inner surface of the base material, and a transverse and longitudinal or other cross-net structure is adopted to improve the overall structural strength of the base material and the strength of the locking structure.
Furthermore, a triangular reinforcing rib is arranged between the top wall and the side wall of the core material filling cavity, so that the strength of the floor and the strength of lock catch connection in the floor splicing state are further improved, and the effect of the same strength as that of the solid floor is achieved.
Further, the substrate is an integrated substrate or a modular assembly substrate.
In order to ensure the overall strength and stability of the product, the integrated base material structure is adopted, so that the overall strength of the floor can be improved, and the stripping problem possibly generated by bonding or splicing multiple parts on the surface of the floor is completely avoided.
The modular assembly substrate can greatly improve the flexibility of the product in terms of length, width and thickness.
Further, the assembly substrate includes a frame structure and a finish structure covering an upper end of the frame structure.
The efficiency and the manufacturing cost of the injection molding production are considered, the base material can be further disassembled, the base material can be made into a frame structure and a surface layer structure covering the upper end of the frame structure, the upper surface of the frame structure can be completely covered by the surface layer structure, and the using effect of a product cannot be influenced.
Further, in order to provide various frame forms, the frame structure is a fixed frame formed by integral injection molding or a combined frame formed by modular assembly.
Further, the overall thickness of the substrate is recommended to be 8mm to 15 mm. But other thicknesses are completely possible, and the larger the thickness is, the more advantageous the cost performance of the product is, and especially, the current stone plastic floor can only be 8mm at the maximum thickness, which is incomparable.
In order to ensure the strength of the lock catch, the whole thickness of the base material is at least 4-8 times of the thickness of the traditional stone plastic floor in the height direction, so that the connection strength of the lock catch can be strengthened to the maximum extent, at least double that of the current 4-6 mm floor.
Furthermore, in order to provide a concrete combination formula frame, combination formula frame includes a plurality of frames that can lock each other, and adjacent frame makes up the length limit or the width limit that make up the floor respectively, be equipped with in the combination formula frame can with the frame on correspond the strengthening rib of position lock.
Because the equipment for producing the stone plastic floor can only adopt extrusion molding equipment to produce and can only produce materials with the thickness of 3.5-8mm, the design of the molding floor in the technical scheme that the molding floor passes through the modularized assembling base material can firstly produce the frame independently in a mode of adopting mold forming by the existing equipment, and then the floor with any size and any thickness is assembled, the production of the floor with any size and any thickness can be realized, the thickness is higher, the cost performance is higher, the adjustment can be carried out according to the specific applicable scene, and the design is considered from the cost of production equipment, and the production cost is reduced to a great extent.
Furthermore, in order to facilitate the fastening between the floors, the frame is provided with a locking structure.
The invention has the beneficial effects that: the technical scheme is to overcome the defects of the prior stone-plastic/plastic floor, the floor is fundamentally improved in structure, meanwhile, the core material is made of the low-density foaming waterproof material, so that the floor also keeps the perfect waterproof performance, in addition, the foaming material can have more excellent performances such as silence, heat insulation, elasticity and the like, particularly, compared with a commonly used 2-3mm base mat at present, the performance can be greatly improved, meanwhile, the stability of the base material is further improved by the core material, and the material of the core material can be selected according to the use environment and the purpose, so that the application environment of the floor is increased. Specifically, the floor structure is changed from a common plane structure to a base material with at least one core material filling cavity, and the base material is made of a high-strength material such as SPC (super cold press), so that the strength and the stability of the whole structure of the floor are ensured; the core material is filled in the core material filling cavity, and the core material is made of a low-density material, so that a high-thickness and low-cost floor product is possible. The design combining the base material made of the high-strength material and the core material made of the low-density material has the structural advantages that the material cost and the weight of the stone-plastic floor are greatly reduced, the material cost of the stone-plastic floor with high thickness, such as the stone-plastic floor with the thickness of 12mm or more, is very competitive, and meanwhile, the transportation cost is greatly reduced due to the fact that the weight of the product is greatly reduced.
In addition, as the core material is filled in the core material filling cavity, the upper end and the periphery of the core material are completely surrounded by the base material, namely, the base material can provide good protection for the core material, and the structure completely avoids the condition that the two-layer or multi-layer structure of the common floor causes delamination due to poor gluing quality.
In conclusion, the structural design of the floor board in the technical scheme reduces the use thickness of the high-strength material under the condition of ensuring enough strength and hardness in the use process of the floor board, so that the high-strength raw material is greatly saved, the cost of the raw material is reduced, and meanwhile, because the weight of the floor board is greatly reduced, the packing amount of floor board transportation is greatly improved under the condition of the same weight limit, and the transportation cost is further reduced. That is, the design can reduce the production cost of products and the weight under the condition of greatly increasing the thickness of the floor, thereby greatly reducing the transportation cost, the density of the core material is low, the waterproof floor which is thicker than the current market can be produced, and the cost is greatly reduced; the thickness is increased, and the performances of heat insulation, moisture insulation, sound insulation and the like of the floor can be greatly improved.
Drawings
FIG. 1 is a schematic view of the structure of the present invention;
FIG. 2 is a schematic side view of the present invention;
FIG. 3 is a schematic view of the internal structure of the substrate according to the present invention;
FIG. 4 is a schematic structural diagram of another embodiment of the present invention;
FIG. 5 is a schematic view of the structure of the frame structure of the present invention;
FIG. 6 is a schematic structural view of another embodiment of the frame structure of the present invention;
FIG. 7 is a schematic structural view of a core and frame structure in an assembled state according to the present invention;
FIG. 8 is a schematic structural view of a surface layer structure and a frame structure filled with a core material in an assembled state according to the present invention;
FIG. 9 is a schematic view of the structure of the substrate integrally formed in the present invention;
FIG. 10 is a schematic view of a plurality of frames to be assembled into a suitable frame structure in accordance with the present invention;
FIG. 11 is a schematic view of a plurality of frames assembled into a suitable frame structure according to the present invention;
FIG. 12 is a schematic view of another assembled bezel of the present invention;
fig. 13 is a schematic structural view illustrating the disassembled combined frame of the present invention.
FIG. 14 is a schematic bottom view of the unitary substrate of the present invention;
FIG. 15 is a schematic top view of the unitary substrate of the present invention;
fig. 16 is a schematic structural diagram of the profiled floor.
In the figure: a substrate 1; a core material 2; a core material filling cavity 3; a latch structure 4; a grid-like reinforcing rib 16; triangular reinforcing ribs 17; a frame structure 18; a face layer structure 19; a combined frame 20; a groove 21; a columnar support 22; and a reinforcing rib 23.
Detailed Description
Example 1:
as shown in fig. 1-16, the present embodiment provides a novel molded floor, which includes a base material 1 and a core material 2, wherein the base material 1 has at least one core material filling cavity 3, the core material 2 is filled in the core material filling cavity 3, and a locking structure 4 connected with an adjacent floor is circumferentially arranged on a side surface of the base material 1; the base material 1 is made of a high-strength waterproof material, and the core material 2 is made of a low-density foaming waterproof material.
The technical scheme is to overcome the defects of the prior stone-plastic/plastic floor, the floor is fundamentally improved in structure, meanwhile, the core material 2 is made of a low-density foaming waterproof material, so that the floor also keeps the perfect waterproof performance, in addition, the foaming material can have more excellent performances such as silence, heat insulation, elasticity and the like, particularly, the performance of the floor can be greatly improved compared with the prior commonly used 2-3mm base mat, meanwhile, the stability of the base material 1 is further improved by the core material 2, the material of the core material 2 can be selected according to the use environment and the purpose, and the application environment of the floor is improved. Specifically, the floor structure is changed from a common plane structure to a base material 1 with at least one core material filling cavity 3, and the base material 1 is made of a high-strength material such as SPC (SPC), so that the strength and the stability of the whole structure of the floor are ensured; the core material 2 is filled in the core material filling cavity 3, and the core material 2 is made of a low-density material, so that a high-thickness and low-cost floor product is possible. The design of combining the base material 1 made of the high-strength material and the core material 2 made of the low-density material has the structural advantage of greatly reducing the material cost and the weight of the stone-plastic floor, and the stone-plastic floor with high thickness, such as the stone-plastic floor with the thickness of 12mm or more, cannot be produced due to the limitation of the technology and equipment for producing the stone-plastic floor at present.
In addition, because the core material 2 is filled in the core material filling cavity 3, the upper end and the periphery of the core material 2 are completely surrounded by the base material 1, namely, the base material 1 can provide good protection for the core material 2, and the structure completely avoids the condition that two layers or multiple layers of structures in the common floor cause delamination due to poor gluing quality. In addition, the high density of the base material 1 enables the tensile strength of the latch structure 4 to be maintained, and the latch structure 4 is not affected at all by the core material 2.
In conclusion, the structural design of the floor board in the technical scheme reduces the use thickness of the high-strength material under the condition of ensuring enough strength and hardness in the use process of the floor board, so that the high-strength raw material is greatly saved, the cost of the raw material is reduced, and meanwhile, because the weight of the floor board is greatly reduced, the packing amount of floor board transportation is greatly improved under the condition of the same weight limit, and the transportation cost is further reduced. That is, the design can reduce the production cost of products and the weight under the condition of greatly increasing the thickness of the floor, thereby greatly reducing the transportation cost, the density of the core material 2 is low, and the waterproof floor which is thicker than the current market can be produced, and the cost is greatly reduced; the thickness is increased, and the performances of heat insulation, moisture insulation, sound insulation and the like of the floor can be greatly improved.
Compared with the common SPC floor, the cost of the whole material of the technical scheme is greatly reduced, and the laminated SPC floor can be compared favorably with a reinforced floor with the same thickness.
The molded floor adopting the technical scheme has the advantages of high thickness, high performance, multifunction, low cost and water resistance, and cannot be achieved by the existing stone-plastic floor.
Specifically, this molding floor has the possibility of multiple extended function development, thereby can carry out the functional of special design increase floor through the material that the adjustment core chooseed for use or to the structure of core, for example the core adopts elastic material, thereby promote the comfort level that the floor foot was stepped on, perhaps the embedded ground heating coil of establishing of core, thereby can realize laying the laying of ground heating coil when laying the floor, saved and need lay the process of ground heating coil in the floor below alone, more save the construction process.
Example 2:
this example was optimized based on example 1 described above.
The upper surface of the substrate 1 is sequentially provided with a wear-resistant layer and a decorative layer, the wear-resistant layer is positioned on the upper surface of the decorative layer, and the decorative layer is directly printed on the surface of the substrate.
The substrate 1 may be embedded with a plurality of layers of the core material 2, and the number of layers, number, and material of the core material 2 may be set specifically according to the use environment and the demand, and is not particularly limited. Preferably, the core 2 should be flat to ensure good contact and adhesion with the substrate 1 and other layers.
The material and/or thickness of each layer of core material 2 may be different to suit different application scenarios and usage requirements.
Since the core material 2 is inside the base material 1, the density thereof can be much lower than that of the base material 1 itself, and at the same time, sufficient supporting strength is provided, and the material density of the core material 2 can be selected and controlled according to the use environment. The core 2 can be made of materials with different properties, so that the flooring with different requirements, such as hard flooring, resilient flooring or other desired flooring, can be produced according to the requirements of customers or environment, while ensuring sufficient strength, hardness and toughness of the flooring surface. In addition, according to the requirements of customers or use environments, the core material 2 can be replaced by any material with appropriate density, so that the use range and the diversity of performance of the product are greatly improved.
The core material 2 can also adopt a multi-layer structure, and materials with different thicknesses and different varieties can be used in each layer according to market requirements, so that the comfort level, the heat insulation performance, the sound insulation performance and the like of the product are improved, and the development of different series of products is facilitated.
For example, the core material 2 may be selected from low-density foam waterproof materials such as PVC, PP, PE, EVA, TPU, EPDM, and rubber. The low-density material provided by the technical scheme has the advantages that the density of the low-density material can be only up to the level of supporting the weight on the floor, such as walking of people and placement of furniture and household equipment; the choice of materials can be tailored to the context of use, such as a home, commercial, or industrial application context, and the like.
The substrate can also adopt an assembled waterproof structure, such as a small square frame structure, the small square frames are connected to form the length required by the substrate, the surface of the substrate is pasted with required materials, the required materials can be waterproof plastic materials, and can also be other materials, and the square frame (namely the core material filling cavity) is filled with the core material;
the base material can also adopt a completely separated spare part structure, the spare parts are firstly combined into a square frame, are sequentially connected, are combined into the required length and width of the base material, and then are pasted with the required material on the surface, such as a waterproof plastic material, and can also be other materials, and the square frame (namely the core material filling cavity) is filled with the core material.
Example 3:
this embodiment is optimized based on embodiment 1 described above.
The density of the low-density foaming waterproof material is 100kg/m 3 -800kg/m 3 The density of the high-strength waterproof material is more than 800kg/m 3
In the technical scheme, the core material 2 is arranged in the base material 1, so that the density of the core material 2 can be as low as 100kg/m 3 Thus, the overall cost and weight of the floor can be greatly reduced, and the transportation cost can be further reduced.
It should be noted that the substrate 1 can be made of a material with high strength, high hardness, water resistance, sanitation, safety and certain toughness, such as a stone-plastic material (plastic + stone powder + additive), so as to ensure the strength and hardness of the surface, and is suitable for use in home and commercial environments.
Example 4:
this embodiment is optimized based on embodiment 1 described above.
As shown in fig. 1, 2, 4 and 7, the lower end surface of the core material 2 positioned at the lowest part is provided with a groove 21, preferably, the lowest end of the core material 2 can exceed the lower end of the base material 1 by 2-4 mm. Or more, depending on market and customer needs.
The bottom of the core material 2 is provided with a groove 21, so that the lower end of the floor is of a hollow structure, and redundant water can be discharged in a shunting manner more easily and more quickly; in addition, a layer of air is kept between the ground and the floor, so that the heat insulation performance of the product is improved, the growth of mould is reduced, and the floor does not need to be replaced completely after the surface of the floor is cleaned, so that the use cost is greatly saved; the condition that the ground is soaked by a large amount of water is small, the lowest end of the core material 2 exceeds the lower end of the base material 1 by 2-4mm or more, the floor is in cylindrical contact with the ground, and a sufficient gap is reserved between the back of the floor and the ground, so that water below the floor can flow freely and be emptied, mildew and bacteria are avoided, the cleanness and sanitation of the environment are kept, meanwhile, a new floor is not needed, and the loss caused by water damage is greatly saved; in addition, the lower end of the floor is of a hollow structure, the shock resistance of a product is improved, noise transmission is reduced, a shock-absorbing/sound-insulating ground mat is not needed, the comfort degree of walking on the floor is improved, and meanwhile, due to the structural design of the grooves 21, the use of materials is saved.
The depth of the grooves 21 may be 1/2-3/4 of the thickness of the core 2, the grooves 21 have a hemispherical structure, which ensures that the floor has an optimal resistance under gravity, and the part contacting the ground is the columnar support 22 between the adjacent grooves 21.
Example 5:
this example was optimized based on example 1 described above.
As shown in fig. 3, 6, and 14, a lattice-shaped rib 16 is provided inside the base material 1, and the core material filling cavity 3 is divided into a plurality of sections by the lattice-shaped rib 16.
In order to enhance the overall strength of the base material 1, it is necessary to have grid ribs 16, and the grid ribs 16 are formed on the inner surface of the base material 1, and adopt transverse and longitudinal or other cross-net structures to enhance the overall structural strength of the base material 1 and the strength of the latch structure 4.
As shown in fig. 3, 5-7, a triangular reinforcing rib 17 is further disposed between the top wall and the side wall of the core material filling cavity 3, so as to further improve the strength of the floor board itself and the strength of the locking connection in the floor board splicing state, and achieve the same strength as that of the solid floor board.
Example 6:
this embodiment is optimized based on embodiment 1 described above.
The substrate 1 is a one-piece substrate 1 or a modular assembly substrate 1.
As shown in fig. 1-4, 9, 14 and 15, in order to ensure the overall strength and stability of the product, the integrally formed base material 1 is adopted, and the material of the base material 1 is the same, so that the overall strength of the floor can be improved, and the peeling problem possibly caused by bonding or splicing of multiple positions on the surface of the floor can be completely avoided.
As shown in fig. 5-8, 10-13, the modular assembly substrate 1 can greatly improve the flexibility of the product in terms of length, width and thickness.
Example 7:
this embodiment is optimized based on embodiment 6 described above.
As shown in fig. 8, the assembled substrate 1 includes a frame structure 18 and a facing structure 19 covering an upper end of the frame structure 18.
Considering injection moulding production's efficiency and manufacturing cost, this base material 1 can further be disassembled, and frame construction 18 and the surface course structure 19 that covers in frame construction 18 upper end can be made to base material 1, and surface course structure 19 can cover frame construction 18's upper surface completely, can not influence the product result of use, and this kind of design needs to guarantee that the material that surface course structure 19 adopted is high strength waterproof material, and frame construction 18 can be the same with the material of core 2.
Example 8:
this embodiment is optimized based on embodiment 7 described above.
To provide a variety of bezel configurations, the frame structure 18 can be an integrally injection molded fixed bezel (as shown in fig. 5) or a modular assembly of modular bezels 20 (as shown in fig. 6-8).
The fixed frame or modular frame 20 is described in detail below:
fixing a frame: as shown in fig. 5, the frame body (four sides) is produced by injection molding or other production methods, the long side and the short side are directly provided with the lock catches (not shown in the figure), and the four sides of the frame body have enough height to ensure the structure and the strength of the lock catch structure; the middle of the frame body can be filled with reinforcing ribs (as shown in figure 6).
Combined rim 20 (shown in fig. 6-8): four edges of the frame body can be produced separately and then assembled into a frame; the long-side belt lock catches (not shown in the figure) can be independently injected; the terminal band lock (not shown in the figure) is additionally produced; the end heads and the long edges are provided with the inserting devices, so that the connection of the frame bodies is ensured, glue can be supplemented, and the connection strength is enhanced; the middle reinforcing rib can also be produced independently and spliced with the two long edges.
Combined ruler long frame (as shown in fig. 10 and fig. 11):
the two long sides can be made into fixed length standard lengths; a long side belt locking device; one end of each long side is provided with a female buckle, and the other end of each long side is provided with a male tenon so as to be conveniently spliced with other long sides, so that the length required by a customer can be any length, such as 3 feet, 4 feet or 5 feet; the reinforcing ribs are produced independently and are spliced with the long edges; each frame is provided with at least two reinforcing ribs, the end heads of the reinforcing ribs are vertically connected with the long edges in an inserted manner, and one reinforcing rib can be added in the middle of each frame to further ensure the stability of the frame; the long-edge end is provided with two groups of inserting devices, one group is used for connecting the frame, and the other group is used for connecting the next group of frames or end locking plates; when the total length of the combined frame meets the requirement, the two ends of the combined frame form a complete floor frame by using end plates inserted with latches; when the whole frame is assembled, the core material 2 can be embedded into the frame; the core material 2 is produced independently and is matched with the groove to be connected with the reinforcing rib; after the core material 2 is inlaid, the next step is carried out, and the floor surface layer structure 19 is glued on the whole surface of the frame, so that the whole combination of the floor is completed.
The combination mode of the square plates (as shown in fig. 9):
this combination, slightly different from the fixed frame structure, is to make the frame to a standard length (one foot length) to length; the core material 2 can be directly injected into the frame to form a whole plate; the long side belt lock catch is provided with a connecting device for plugging at the end; a female slot at one end of the frame; the other end of the frame is provided with a male tenon; the frames are inserted into each other to reach the ideal length, such as 3 feet, 4 feet or 5 feet; the end plates with the lock catches are separately produced and provided with female slots or male tenons which are inserted so as to be perfectly connected with the frame; the width of the square frame determines the whole width of the floor, and the floors with different widths are either opened independently or the inserts of the mold are adjusted; the length of the end catch plate is produced according to the width of the frame.
The core material 2 and the frame can be cast and produced simultaneously, and the core material and the frame are integrated after coming out of the mould; or the core material 2 and the frame are produced separately and then embedded and combined together; after the combination of the core material 2 and the frame is finished, the storage is carried out, or the next production link is directly carried out. The two long sides can be made into fixed length standard lengths; long side belt lock catch structure.
The face layer structure 19 is produced in the following manner: when the core 2 and the frame structure 18 are integrated, the surface layer structure 19 can be directly bonded on the top (as shown in fig. 7 and 8), and the process and the structure have the advantages that not only the waterproof plastic floor can be produced, but also other materials can be bonded, for example, the surface layer structure 19 can be wood skin, and then the solid wood composite floor is formed.
The characteristics of the combined frame are as follows:
compared with a fixed frame, the frame is split into four parts, so that the size of the die is greatly reduced, and the investment of die cost is greatly reduced; the small-sized parts also reduce the difficulty of injection molding production and improve the production efficiency; although the length is fixed, the width can be adjusted by the length of the end plates and the reinforcing ribs.
The fixed-length combined frame has the characteristics that:
because the length of the long side is fixed at the length of one foot, the structure can improve the flexibility of the floor in length, width and even thickness to the maximum extent; the length of the long side is fixed to be one foot; the width is determined by the reinforcing ribs and the end plates; after the sizes of all parts are reduced, the cost of a mould and the cost of equipment are greatly reduced, meanwhile, multi-cavity injection molding is easier, and the production efficiency can be greatly improved; different series of floor products can be combined due to the size change, such as floors with matched long and short plates, floors with matched wide and narrow plates and floors with different lengths and widths, and the floor combined by matching has more vivid and beautiful installation effect; although the assembly of components adds to the process and cost of assembly, the plug-in devices are standard and can be easily implemented in an automated line.
The surface layer structure 19 has the following characteristics:
the structure is different from a combined frame, the core material 2 and the frame are integrated into a square block, and the square block is connected and combined with the square block; compared with the component combination of parts, the combination speed and the combination efficiency are greatly improved; because the length of the square block is fixed at one foot, compared with the large-size base material 1, the size of the die is greatly reduced, not only is the initial investment reduced, but also more cavities are easier to realize, the injection time is correspondingly shortened, and the production efficiency is greatly improved; the mounting of the blocks in one foot length also provides flexibility in length to meet different market needs.
Example 9:
this embodiment is optimized based on embodiment 8 described above.
As shown in fig. 11, in order to provide a specific combined type frame, the combined type frame 20 includes a plurality of frames that can be fastened to each other, adjacent frames are respectively combined to form a length edge or a width edge of the floor, and a reinforcing rib 23 that can be fastened to a corresponding position on the frame is provided in the combined type frame 20.
Because the existing equipment for producing the stone plastic floor only can adopt extrusion molding equipment to produce and can only produce materials with the thickness of 3.5-8mm, the molded floor in the technical scheme can firstly produce the frame independently by adopting a mode of molding a mould through the existing equipment through the design of modular assembly base materials, and then assemble the floor with any size and any thickness, and can realize the production of the floor with any size and any thickness, and the higher the thickness is, the higher the cost performance is, the adjustment can be carried out according to a specific applicable scene, and the design is considered from the cost of production equipment, so that the production cost can be reduced to a great extent.
Example 10:
this embodiment is optimized based on embodiment 9 described above.
In order to facilitate the fastening between the floors, the frame is provided with a locking structure.
Example 11:
this embodiment is optimized based on embodiment 1 described above.
The overall thickness of the substrate 1 is recommended to be 8mm to 15 mm. Or more, but other thicknesses are completely possible, and the larger the thickness is, the more advantageous the cost performance of the product is, especially for the current stone plastic floor, the thickest can only be 8mm, which is incomparable.
In order to ensure the strength of the locking device, the overall thickness of the base material 1 is at least 4-8 times of the thickness of the traditional stone plastic floor in the height direction, so that the connection strength of the locking device can be reinforced to the maximum extent, at least twice of the current 4mm-6mm floor.
In the technical scheme, the surface treatment of the floor is explained as follows:
at present, the main surface treatment modes of the plastic floor comprise a color film decorative layer, a wear-resistant layer and a scratch-resistant coating. Except the coating, the other two layers are produced separately and purchased from different suppliers, and the coating is finished by a paint line.
The disadvantages of procurement of the skin layer are: the production capacity and process of the floor factory is to some extent limited by the colour film supplier; each color has the lowest order quantity, so that a large amount of stock is inevitably generated, particularly when new colors are developed; on the other hand, if a certain design is hot sold, the delivery date is greatly influenced if the production is not available from outside purchase. In addition, because the surface of the plastic floor is still made of plastic materials, scratch marks are easy to appear in the using process, and no effective solution exists in the floor industry at present.
In order to solve the quality production problem, a production mode and a process which are completely different from the above can be adopted.
Surface decoration layer: high-speed printing equipment designed and controlled by a computer; any pattern and pattern can be designed and produced according to the requirements of customers or markets, the control is completely independent, the limitation of the number, the cost, the delivery date and the like of the suppliers of the decorative layer is avoided, and the zero stock is really realized; definition of pattern/texture; the consistency of different batches with the same color is greatly improved, and the complete consistency can be basically achieved; the three-dimensional effect of the texture 3D is far higher than that of a pattern matching mode adopted in the current industry, and zero error is realized; 3D register effect on the surface of the stone can be printed vividly, and the existing register mode is not available or the cost is too high; because the high-speed printing is adopted, the efficiency is greatly improved, and because the printing is directly carried out on the surface of the floor, the material cost of the color film and the wear-resistant layer is also saved.
Wear and scratch resistance:
aiming at the defect of poor scratch resistance of the surface of the existing plastic floor, high-wear-resistance scratch-resistant glue is adopted to be coated on the surface, so that the problem of surface scratch resistance existing in the series of floors at present is completely solved. Or other materials such as TPU or EDPM can be used, and the thickness of the coating can be adjusted, so that different series of floors such as elastic floors can be produced to meet the market demand; although the material cost of TPU or EDPM is more expensive than that of the common wear-resistant adhesive, the color film and the wear-resistant material are saved, the increase of the cost can be balanced to a certain degree, and in addition, more importantly, the materials are free of formaldehyde, and meanwhile, the high-efficiency wear resistance and scratch resistance are provided, so that great benefits are brought to the health and comfortable use of consumers.
As shown in FIG. 16, due to the change of the manufacturing process, another important feature of the designed floor is that various shaped floors, such as wavy, S-shaped or even round floors, can be produced; in combination with surface printing techniques, almost unlimited patterns or shapes can be created.
In addition, the decoration of the surface can be changed from the currently popular outsourcing color film to be directly printed on the surface of the floor, so that the zero stock of the decoration layer material can be realized, the requirements of customers on colors and colors can be timely and quickly met, and the requirement of no minimum production can be realized; wear and scratch resistance, and process adjustment, and the surface adopts direct covering materials to protect the decoration without an externally purchased wear-resistant layer. The covering material can adjust the variety and the thickness according to the requirements of customers and markets, so that the wear resistance and the scratch resistance of the surface are greatly improved, and the comfort level of the surface of the floor is improved; due to the change of the manufacturing process of the floor, the floor can not be flat any more, and various shapes of floors can be produced.
At present, plastic floors are all extruded. The floor adopting the technical scheme can adopt the following various production modes:
the base material 1 is suggested to adopt an injection molding mode, and the locking structures 4 can be simultaneously injected out, so that the investment of a slotting production line and a slotting production process are saved; the surface and the frame of the substrate 1 are simultaneously injected, namely the substrate is integrally formed; the frame structure 18 is produced by injection molding, and the surface can be produced by extrusion molding; the core material 2 may be produced by injection molding simultaneously with the frame, or may be produced separately and then combined with the frame; the multilayer core material 2 can be produced independently or can be injected with the base material 1 at the same time; the frame structure 18 is formed by injection molding of a frame and is provided with a locking device or is combined with the core material 2 in an injection cavity or is bonded together after being demoulded; floor surfaces, either purchased externally (such as wood veneer) or extruded (such as SPC) depending on the material and then glued to the frame; the injection molding process offers the possibility of multiple variations in the production of profiled flooring, and the process equipment is very mature and does not have problems in mass production.
The floor provided by the technical scheme has good structural strength and is superior to the floor with the density of 800kg/m 3 The structural strength of the solid floor.
In general, the technical scheme structurally modifies the traditional floor comprehensively, meanwhile, the decorative layer on the surface is directly printed, then materials with high wear resistance and scratch resistance are added, the product performance is greatly improved, the cost is reduced, and the stone plastic floor with high thickness (more than 8mm) is possible, because the existing equipment for producing the stone plastic floor only can adopt extrusion molding equipment for production and can only produce materials with the thickness of 3.5-8mm, the molded floor in the technical scheme can firstly produce a frame independently through the modularized assembly base material design by adopting a mold forming mode through the existing equipment, then the floor with any size and any thickness is assembled, the production of the floor with any size and any thickness can be realized, the higher the thickness is, the higher the cost performance is, the adjustment can be carried out according to specific applicable scenes, and the design is considered from the production equipment cost, the production cost is also greatly reduced.
Finally, it should be noted that: the above are merely preferred embodiments of the present invention, and are not intended to limit the scope of the present invention. Any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the protection scope of the present invention.

Claims (10)

1. A novel molded floor, characterized in that: the floor board comprises a base material and a core material, wherein the base material is at least provided with a core material filling cavity, the core material is filled in the core material filling cavity, and a lock catch structure connected with an adjacent floor board is arranged on the circumferential direction of the side surface of the base material; the base material is made of a high-strength waterproof material, and the core material is made of a low-density foaming waterproof material.
2. The novel molded floor as claimed in claim 1, wherein: the upper surface of the base material is sequentially provided with a wear-resistant layer and a decorative layer, and the wear-resistant layer is located on the upper surface of the decorative layer.
3. The novel molded floor as claimed in claim 1, wherein: the density of the low-density foaming waterproof material is 100kg/m 3 -800kg/m 3 The density of the high-strength waterproof material is more than 800kg/m 3
4. The novel molded floor as claimed in claim 1, wherein: the bottom of the core material positioned at the lowest part is provided with a groove.
5. A novel molded floor as claimed in claim 1, wherein: the inside of the base material is provided with a grid-shaped reinforcing rib, and the core material filling cavity is divided into a plurality of cavities by the grid-shaped reinforcing rib.
6. The novel molded floor as claimed in claim 1, wherein: the substrate is an integrated substrate or a modular assembled substrate.
7. The novel molded floor as claimed in claim 6, wherein: the assembly substrate includes a frame structure and a finish structure covering an upper end of the frame structure.
8. The novel molded floor as claimed in claim 7, wherein: the frame structure is a fixed frame formed by injection molding or a combined frame formed by modular assembly.
9. The novel molded flooring of claim 8, wherein: the combined type frame comprises a plurality of frames which can be mutually buckled, the adjacent frames are respectively combined into the length edge or the width edge of the floor, and reinforcing ribs which can be buckled with the corresponding positions on the frames are arranged in the combined type frame.
10. The novel molded floor of claim 9, wherein: and a lock catch structure is arranged on the frame.
CN202210519305.8A 2022-05-12 2022-05-12 Novel molding floor Pending CN115030437A (en)

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Application Number Priority Date Filing Date Title
CN202210519305.8A CN115030437A (en) 2022-05-12 2022-05-12 Novel molding floor
PCT/CN2022/102104 WO2023216388A1 (en) 2022-05-12 2022-06-29 Novel molded flooring
CA3233886A CA3233886A1 (en) 2022-05-12 2022-06-29 Framed (modular) plastic composite

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CN202210519305.8A CN115030437A (en) 2022-05-12 2022-05-12 Novel molding floor

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Publication number Priority date Publication date Assignee Title
BE1014095A5 (en) * 2001-04-03 2003-04-01 Floor-of wall panel of plastic and method for manufacturing same.
JP4225173B2 (en) * 2003-09-12 2009-02-18 パナソニック電工株式会社 Manufacturing method for flooring
CN201288379Y (en) * 2008-08-25 2009-08-12 卢文成 Plastics base hollow section bar filled with cement base foam material
CN201411887Y (en) * 2009-03-31 2010-02-24 南京闽磊建材实业有限公司 Inserted fast-assembling plastic floor
CN104631761A (en) * 2015-02-12 2015-05-20 安吉恒丰竹木产品有限公司 Light composite floor board
CN210217022U (en) * 2019-04-24 2020-03-31 刘文晓 Floor splicing structure and floor thereof
CN113389346A (en) * 2021-07-01 2021-09-14 黄焕文 Combined bottom plate frame, bottom plate and spliced floor
CN216196291U (en) * 2021-10-18 2022-04-05 浙江元森态木塑科技股份有限公司 Plastic-wood floor and combined system thereof
CN217871568U (en) * 2022-05-12 2022-11-22 10957402加拿大公司 Novel molding floor

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