CN115139604B - 一种高强低膨胀塑胶地板及其制备方法 - Google Patents
一种高强低膨胀塑胶地板及其制备方法 Download PDFInfo
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Abstract
本发明涉及E04F技术领域,更具体地,本发明涉及一种高强低膨胀塑胶地板及其制备方法。高强低膨胀塑胶地板,依次包括耐磨层、印刷层、中料层、底料层、防析出层。本申请所述高强低膨胀塑胶地板能够有效阻止增塑剂的析出问题,同时具有优异的力学性能。
Description
技术领域
本发明涉及E04F技术领域,更具体地,本发明涉及一种高强低膨胀塑胶地板及其制备方法。
背景技术
塑胶地板又称PVC地板,在欧美及亚洲广受欢迎。CN201821984682通过使用PVC耐磨层、PVC装饰层、PVC片材、PVC发泡层等得到一种新型复合地板,具有较好的隔音效果,然而该复合地板存在小分子增塑剂易于析出,膨胀率高、直线度差的问题。CN201110182685提供了一种PVC塑木贴面企口地板,通过使用PVC材料、润滑剂等材料得到木质地板层,得到的地板涨缩均匀,然而其存在尺寸稳定性的问题,膨胀收缩率无法满足生产的要求。此外,现有的塑胶地板还存在刚性差,容易受到外力变形,受热胀冷缩影响发生尺寸变化,导致拼接处产生缝隙或变形,粘结强度降低等问题。
发明内容
针对现有技术中存在的一些问题,本发明第一个方面提供了一种高强低膨胀塑胶地板,包括依次连接的耐磨层、印刷层、中料层、底料层、防析出层。
在一种实施方式中,按重量份计,所述耐磨层的制备原料包括60-70份PVC树脂粉、20-30份增塑剂、0.5-1份稳定剂、5-10份硅酸盐矿物质。
在一种优选的实施方式中,按重量份计,所述耐磨层的制备原料还包括0.5-1份抗氧化剂、0.5-1份抗紫外线剂。
在一种更优选的实施方式中,按重量份计,所述耐磨层的制备原料包括65份PVC树脂粉、25份增塑剂、0.8份稳定剂、8份硅酸盐矿物质、0.7份抗氧化剂、0.6份抗紫外线剂。
优选的,所述PVC树脂粉的聚合度为800-1000,优选为845-980。
优选的,所述PVC树脂粉根据ASTM D-I243-58T得到的特性粘度为0.8-1dL/g,更优选为0.89-0.95dL/g。
更优选的,所述PVC树脂粉的型号为SG-5。
申请人意外的发现,当PVC树脂粉的聚合度为800-1000时,得到的塑胶地板的硬度较高,申请人认为可能的原因是该特定聚合度的PVC树脂粉具有合适长度的分子链,增大了塑胶地板的分子之间的作用力。此外,申请人意外的发现,当PVC树脂粉的特性粘度为0.8-1dL/g时,在制备过程中流动性好。
本申请所述增塑剂不作特别限定,本领域技术人员可作常规选择。
在一种实施方式中,所述增塑剂为对苯二甲酸二辛酯。
本申请所述稳定剂不作特别限定,本领域技术人员可作常规选择。
在一种实施方式中,所述稳定剂为钙锌稳定剂。
本申请所述抗氧化剂、抗紫外线剂不作特别限定,本领域技术人员可作常规选择。
优选的,所述硅酸盐矿物质在25℃的密度为2.5-3g/cm3,更优选为2.65g/cm3。
进一步优选的,所述硅酸盐矿物质包括(a)粒径为40-60目的硅酸盐矿物质和(b)粒径为90-120目的硅酸盐矿物质;更优选的,所述硅酸盐矿物质包括(a)粒径为50目的硅酸盐矿物质和(b)粒径为100目的硅酸盐矿物质。
优选的,所述硅酸盐矿物质为石英砂。
在一种实施方式中,所述(a)粒径为40-60目的硅酸盐矿物质和(b)粒径为90-120目的硅酸盐矿物质的重量比为(0.6-1.5):1,优选为1:1。
申请人在实验中发现,当采用本申请中特定的PVC树脂粉在得到一定硬度的塑胶地板时,使用常规的无机填料来提高防滑性时,防滑等级比较低,此外,本申请在实验中意外的发现,当使用特定含量的硅酸盐矿物质,尤其是硅酸盐矿物质包括(a)粒径为40-60目的硅酸盐矿物质和(b)粒径为90-120目的硅酸盐矿物质时,此时防滑等级较高,同时与印刷层之间复合的强度增大,申请人认为可能的原因是该特定粒径的硅酸盐矿物质,特别是密度为2.5-3g/cm3,在耐磨层各个原料混合搅拌时能够与分子链较长的PVC分子相互协调,在耐磨层的制备过程中,不同粒径的硅酸盐矿物质被较长分子链的PVC分子包裹缠结,使得该2种特定粒径的硅酸盐矿物质呈现一定的分布结构,不仅提高了防滑等级,同时增大了该塑胶地板的耐环境稳定性。
本申请所述印刷层不作特别限定,本领域技术人员可作常规选择。
优选的,所述印刷层的厚度为0.07mm。
在一种实施方式中,按重量份计,所述中料层的制备原料包括17-20份PVC树脂粉、5-7份增塑剂、0.1-1份稳定剂、72-75份无机粉体、1-3份纤维增强材料。
在一种优选的实施方式中,按重量份计,所述中料层的制备原料包括17.5-19份PVC树脂粉、5-6.5份增塑剂、0.5份稳定剂、73-74.5份无机粉体、1-2.5份纤维增强材料。
本申请所述无机粉体不作特别限定,本领域技术人员可作常规选择。
在一种实施方式中,所述纤维增强材料的长度为6-15mm。
优选的,所述纤维增强材料为短切玻璃纤维。
申请人在实验中意外的发现,在本申请中料层特定的原料中加入特定含量的短切玻璃纤维,在一定程度上降低了在23-50℃的膨胀率和80℃的收缩率。
在一种实施方式中,按重量份计,所述底料层的制备原料包括40-45份PVC树脂粉、8-10份增塑剂、0.5-2份稳定剂、40-60份填料。
在一种实施方式中,按重量份计,所述底料层的制备原料包括40-41份PVC树脂粉、8.5-9份增塑剂、1份稳定剂、50份填料。
申请人在实验中意外的发现,当底料层的制备原料包括40-41份PVC树脂粉、8.5-9份增塑剂、1份稳定剂、50份填料时,各个原料之间互相促进,具有较好的直线度,同时抵抗外力变形性较好。
在一种实施方式中,所述防析出层的材质选自TPU薄膜、NBR薄膜、PVC膜中任一种。
优选的,所述防析出层厚度为0.02-0.05mm。
优选的,所述防析出层中不含有增塑剂。
本申请中碳酸钙均为重质碳酸钙。
在一种实施方式中,所述碳酸钙的粒径为180目。
本发明第二个方面提供了一种所述高强低膨胀塑胶地板的制备方法,包括:分别将耐磨层、中料层的各个制备原料混合,经过密炼、开炼、四辊压延、冷却裁切、拉制出片,得到耐磨层、中料层;将底料层的各个制备原料混合,经过密炼、开炼、四辊压延,压延的同时与防析出层复合,之后冷却裁切、拉制出片,得到底料层和防析出层双层产品;将耐磨层、印刷层、中料层、底料层和防析出层双层产品依次叠放热压和冷压贴合,然后对耐磨层表面进行UV处理和回火处理,获得半产品;半成品经过自动削边机削边,即得。
优选的,在长度为36m的回火炉于120-145℃进行回火处理,处理速率为10-12m/min。
在一种实施方式中,所述高强低膨胀塑胶地板的制备方法,包括下面步骤:
(1)将PVC树脂粉、增塑剂、稳定剂共混,搅拌2-3min后加入无机粉体和纤维增强材料,高速搅拌2-3min后,投入密炼机中,物料在密炼机中温度达到120℃后密炼2-6min,之后在开炼机中于150-160℃开炼,然后经过四辊压延、冷却裁切,以30m/min的速度拉制出片完成,获得中料层;
(2)将PVC树脂粉、增塑剂、稳定剂、抗氧化剂、抗紫外线剂共混,搅拌2-3min后加入碳酸钙和石英砂,高速搅拌2-3min后,投入密炼机中密炼2-6min,之后经过开炼、四辊压延、冷却裁切,以30m/min的速度拉制出片完成,获得耐磨层;
(3)将PVC树脂粉、增塑剂、稳定剂共混,搅拌2-3min后加入无机粉体,高速搅拌2-3min后,投入密炼机中密炼2-6min,之后经过开炼、四辊压延,压延的同时与防析出层复合,冷却裁切,以30m/min的速度拉制出片完成,获得底料层和防析出层双层产品;
(4)将耐磨层、印刷层、中料层、底料层和防析出层双层产品依次叠放,在140-150℃于3-8MPa热压贴合30-40min,再10-15MPa进行冷压贴合20-30min,冷压贴合的冷却水温度为28-30℃,然后对耐磨层表面进行UV处理和回火处理,获得半产品,其中在长度为36m的回火炉于130℃进行回火处理,处理速率为11m/min;
(5)将半成品的长度和宽度在尺寸上均预留至少2mm,再用自动削边机削边,获得成品。
本申请高强低膨胀塑胶地板的制备方法中未公开的部分,本领域技术人员可作常规选择。
本发明与现有技术相比具有以下有益效果:
(1)采用本申请特定的PVC树脂粉,得到的塑胶地板的硬度较高,同时制备过程中流动性好;
(2)粒径为40-60目的硅酸盐矿物质和(b)粒径为90-120目的硅酸盐矿物质的复合使用,避免了本申请特定PVC树脂粉带来的防滑等级比较低的问题,同时与印刷层之间复合的强度增大;
(3)中料层特定的原料中加入特定含量的短切玻璃纤维,在一定程度上降低了在23-50℃的膨胀率和80℃的收缩率;
(4)本申请中底料层各个原料之间互相促进,具有较好的直线度,同时抵抗外力变形性较好,软硬度从原先的55D提高到65D,大大提高了产品强度;
(5)使用本申请中特定的防析出层,实现了基材的防DOTP析出功能,同时该防析出层不含增塑剂,其本身不会出现析出的问题,不会影响地板和地面的粘结力,此外具有更优异的止滑耐磨性能;
(6)通过本申请制备方法,短切玻璃纤维能均匀分布在中料层中,有效降低产品膨胀率,克服现有技术地板加工过程中短切玻璃纤维量受限的问题,因为随着短切玻璃纤维量的增加,存在压延时的脱辊,油压时的气泡以及冲切削边时的崩边等技术难题;
(7)本申请中采用热压后冷压的贴合工艺,避免了产生气泡和溢料;
(8)采用特殊的冲切削边工艺避免了崩边现象,要求冲切时尺寸上至少预留2mm,再用自动削边机削边,保证产品不崩边,四边光滑,拼接无缝隙。
具体实施方式
以下通过具体实施方式说明本发明,但不局限于以下给出的具体实施例。
实施例
实施例1
本发明的实施例1提供了一种高强低膨胀塑胶地板,由耐磨层、印刷层、中料层、底料层、防析出层构成。
按重量份计,所述耐磨层的制备原料如下:65份PVC树脂粉、25份对苯二甲酸二辛酯、0.8份钙锌稳定剂、0.7份抗氧化剂、0.6份抗紫外线剂、4份粒径为50目的石英砂、4份粒径为100目的石英砂。
按重量份计,所述中料层的制备原料如下:17.5份PVC树脂粉、6.5份对苯二甲酸二辛酯、0.5份钙锌稳定剂、74.5份碳酸钙、1份短切玻璃纤维。
按重量份计,所述底料层的制备原料如下:40份PVC树脂粉、9份对苯二甲酸二辛酯、1份钙锌稳定剂、50份碳酸钙。
所述防析出层为TPU薄膜,聚酯型95A,厚度为0.05mm。
所述PVC树脂粉型号为SG-5;所述钙锌稳定剂购自济南万得丰环保科技有限公司;所述碳酸钙为重质碳酸钙,粒径为180目;所述短切玻璃纤维的长度为6-15mm,购自桐乡巨石集团。
所述抗氧化剂为抗氧化剂168,所述抗紫外线为紫外线吸收剂UV-531;所述印刷层的厚度为0.07mm,购自大桔。
所述高强低膨胀塑胶地板的制备方法如下:
(1)将PVC树脂粉、增塑剂、稳定剂共混,搅拌2.5min后加入无机粉体和纤维增强材料,高速搅拌2.5min后,投入密炼机中,物料在密炼机中温度达到120℃后密炼5min,之后在开炼机中于155℃开炼,然后经过四辊压延、冷却裁切,以30m/min的速度拉制出片完成,获得中料层;
(2)将PVC树脂粉、增塑剂、稳定剂、抗氧化剂、抗紫外线剂共混,搅拌2.5min后加入碳酸钙和石英砂,高速搅拌2.5min后,投入密炼机中密炼5min,之后经过开炼、四辊压延、冷却裁切,以30m/min的速度拉制出片完成,获得耐磨层;
(3)将PVC树脂粉、增塑剂、稳定剂共混,搅拌2.5min后加入无机粉体,高速搅拌2.5min后,投入密炼机中密炼5min,之后经过开炼、四辊压延,压延的同时与防析出层复合,冷却裁切,以30m/min的速度拉制出片完成,获得底料层和防析出层双层产品;
(4)将耐磨层、印刷层、中料层、底料层和防析出层双层产品依次叠放,在145℃于5MPa热压贴合35min,再12MPa进行冷压贴合25min,冷压贴合的冷却水温度为30℃,然后对耐磨层表面进行UV处理和回火处理,获得半产品,其中在长度为36m的回火炉于130℃进行回火处理,处理速率为11m/min;
(5)将半成品的长度和宽度在尺寸上均预留2mm,再用自动削边机削边,获得成品。
获得的成品在使用过程中未出现增塑剂析出的问题,根据测试标准DIN51130,该塑胶地板的防滑等级为R10。
实施例2
本发明的实施例2提供了一种高强低膨胀塑胶地板,其具体实施方式同实施例1,不同之处在于,按重量份计,所述底料层的成分如下:40.5份PVC树脂粉、8.5份对苯二甲酸二辛酯、1份钙锌稳定剂、50份碳酸钙。所述印刷层的厚度为0.07mm,购自恒昌。
所述高强低膨胀塑胶地板的制备方法其具体实施方式同实施例1。
实施例3
本发明的实施例3提供了一种高强低膨胀塑胶地板,其具体实施方式同实施例1,不同之处在于,按重量份计,所述底料层的成分如下:42份PVC树脂粉、7份对苯二甲酸二辛酯、1份钙锌稳定剂、50份碳酸钙。所述印刷层的厚度为0.07mm,购自华丽。
所述高强低膨胀塑胶地板的制备方法其具体实施方式同实施例1。
实施例4
本发明的实施例4提供了一种高强低膨胀塑胶地板,其具体实施方式同实施例1,不同之处在于,按重量份计,所述中料层的成分如下:17.5份PVC树脂粉、6.5份对苯二甲酸二辛酯、0.5份钙锌稳定剂、73份碳酸钙、2.5份短切玻璃纤维。
所述高强低膨胀塑胶地板的制备方法其具体实施方式同实施例1。
实施例5
本发明的实施例5提供了一种高强低膨胀塑胶地板,其具体实施方式同实施例1,不同之处在于,按重量份计,所述中料层的成分如下:17.5份PVC树脂粉、6.5份对苯二甲酸二辛酯、0.5份钙锌稳定剂、71.5份碳酸钙、4份短切玻璃纤维。
所述高强低膨胀塑胶地板的制备方法其具体实施方式同实施例1。
实施例6
本发明的实施例6提供了一种高强低膨胀塑胶地板,其具体实施方式同实施例1,不同之处在于,按重量份计,所述中料层的成分如下:19份PVC树脂粉、5份对苯二甲酸二辛酯、0.5份钙锌稳定剂、73份碳酸钙、2.5份短切玻璃纤维。
所述高强低膨胀塑胶地板的制备方法其具体实施方式同实施例1。
实施例7
本发明的实施例7提供了一种塑胶地板,其具体实施方式同实施例1,不同之处在于,按重量份计,所述中料层的成分如下:17.5份PVC树脂粉、6.5份对苯二甲酸二辛酯、0.5份钙锌稳定剂、75.5份碳酸钙、0份短切玻璃纤维。按重量份计,所述底料层的成分如下:39份PVC树脂粉、10份对苯二甲酸二辛酯、1份钙锌稳定剂、50份碳酸钙。
实施例8
本发明的实施例8提供了一种市售的PVC塑胶地板,该PVC塑胶地板不含防析出层。
该PVC塑胶地板在使用的过程中出现增塑剂析出的问题,塑胶地板与地面的粘结力变差。
实施例9
本发明的实施例9提供了一种塑胶地板,其具体实施方式同实施例1,不同之处在于,按重量份计,所述耐磨层的制备原料如下:65份PVC树脂粉、25份对苯二甲酸二辛酯、0.8份钙锌稳定剂、0.7份抗氧化剂、0.6份抗紫外线剂。
根据测试标准DIN51130,该塑胶地板的防滑等级为R9。
性能评估
1.膨胀率:分别对实施例1、4-7的塑胶地板在23-50℃的膨胀率进行测试,测试方法如下:将产品放入23℃烘箱中放置6h后,测试得尺寸A,将烘箱温度提高到50℃,6h后测试得到尺寸B,得膨胀率C=(B-A)/A。
2.收缩率:分别对实施例1、4、6、7的塑胶地板在80℃处理6h的收缩率进行测试,测试标准为ISO 23999。
3.硬度:分别对实施例1-3、7的底料层的硬度使用邵氏D硬度计进行测试。
4.直线度:分别对实施例1、2、7的塑胶地板的直线度进行测试,测试标准为ISO24342。
表1
表2
5.翘曲测试:对实施例1的塑胶地板进行翘曲测试,测试标准为ISO 24342。
表3
实施例1 | 实施例7 | |
翘曲 | 0.23mm | 0.5mm |
Claims (3)
1.一种高强低膨胀塑胶地板,其特征在于,包括依次连接的耐磨层、印刷层、中料层、底料层、防析出层;所述耐磨层的制备原料包括60-70份PVC树脂粉、20-30份增塑剂、0.5-1份稳定剂、5-10份硅酸盐矿物质;
所述PVC树脂粉的聚合度为845-980,根据ASTM D-I243-58T得到的特性粘度0 .89-0.95dL/g;
所述硅酸盐矿物质包括(a)粒径为50目的硅酸盐矿物质和(b)粒径为100目的硅酸盐矿物质,所述(a)粒径为50目的硅酸盐矿物质和(b)粒径为100目的硅酸盐矿物质的重量比为1:1;所述硅酸盐矿物质为石英砂;
所述防析出层的材质选自TPU薄膜、NBR薄膜、PVC膜中任一种,所述防析出层厚度为0.02-0.05mm;
按重量份计,所述中料层的制备原料包括17-20份PVC树脂粉、5-7份增塑剂、0.1-1份稳定剂、72-75份无机粉体、1-3份纤维增强材料;
所述纤维增强材料为短切玻璃纤维,所述纤维增强材料的长度为6-15mm。
2.根据权利要求1所述高强低膨胀塑胶地板,其特征在于,按重量份计,所述底料层的制备原料包括40-45份PVC树脂粉、8-10份增塑剂、0.5-2份稳定剂、40-60份填料。
3.一种根据权利要求1-2任一项所述高强低膨胀塑胶地板的制备方法,其特征在于,包括:分别将耐磨层、中料层的各个制备原料混合,经过密炼、开炼、四辊压延、冷却裁切、拉制出片,得到耐磨层、中料层;将底料层的各个制备原料混合,经过密炼、开炼、四辊压延,压延的同时与防析出层复合,之后冷却裁切、拉制出片,得到底料层和防析出层双层产品;将耐磨层、印刷层、中料层、底料层和防析出层双层产品依次叠放热压和冷压贴合,然后对耐磨层表面进行UV处理和回火处理,获得半产品;半成品经过自动削边机削边,即得。
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