CN116922906A - Method for manufacturing floor structure - Google Patents
Method for manufacturing floor structure Download PDFInfo
- Publication number
- CN116922906A CN116922906A CN202210519856.4A CN202210519856A CN116922906A CN 116922906 A CN116922906 A CN 116922906A CN 202210519856 A CN202210519856 A CN 202210519856A CN 116922906 A CN116922906 A CN 116922906A
- Authority
- CN
- China
- Prior art keywords
- layer
- floor structure
- wear
- polyethylene terephthalate
- manufacturing
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 69
- 238000000034 method Methods 0.000 title claims description 23
- 239000000463 material Substances 0.000 claims abstract description 142
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- 229920000139 polyethylene terephthalate Polymers 0.000 claims abstract description 89
- 239000005020 polyethylene terephthalate Substances 0.000 claims abstract description 89
- 239000004698 Polyethylene Substances 0.000 claims abstract description 74
- 229920000573 polyethylene Polymers 0.000 claims abstract description 74
- 239000000758 substrate Substances 0.000 claims abstract description 50
- 239000000853 adhesive Substances 0.000 claims abstract description 48
- 230000001070 adhesive effect Effects 0.000 claims abstract description 48
- 229920008790 Amorphous Polyethylene terephthalate Polymers 0.000 claims description 47
- 229920002799 BoPET Polymers 0.000 claims description 46
- 229920003229 poly(methyl methacrylate) Polymers 0.000 claims description 22
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- RNFJDJUURJAICM-UHFFFAOYSA-N 2,2,4,4,6,6-hexaphenoxy-1,3,5-triaza-2$l^{5},4$l^{5},6$l^{5}-triphosphacyclohexa-1,3,5-triene Chemical compound N=1P(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP=1(OC=1C=CC=CC=1)OC1=CC=CC=C1 RNFJDJUURJAICM-UHFFFAOYSA-N 0.000 description 8
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- CSCPPACGZOOCGX-UHFFFAOYSA-N Acetone Chemical compound CC(C)=O CSCPPACGZOOCGX-UHFFFAOYSA-N 0.000 description 2
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 description 2
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- XTHFKEDIFFGKHM-UHFFFAOYSA-N Dimethoxyethane Chemical compound COCCOC XTHFKEDIFFGKHM-UHFFFAOYSA-N 0.000 description 2
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- 150000008064 anhydrides Chemical class 0.000 description 2
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- 238000000429 assembly Methods 0.000 description 2
- MJOBQUIJUFKMPR-UHFFFAOYSA-N bis(2-hydroxyethyl) 2-[(6-oxobenzo[c][2,1]benzoxaphosphinin-6-yl)methyl]butanedioate Chemical compound C1=CC=C2P(CC(CC(=O)OCCO)C(=O)OCCO)(=O)OC3=CC=CC=C3C2=C1 MJOBQUIJUFKMPR-UHFFFAOYSA-N 0.000 description 2
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Classifications
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- B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
- B32B27/308—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising acrylic (co)polymers
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- E04F15/105—Flooring 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 of organic plastics with or without reinforcements or filling materials
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- E04F15/107—Flooring 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
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- B32B2419/00—Buildings or parts thereof
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- E—FIXED CONSTRUCTIONS
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- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F2290/00—Specially adapted covering, lining or flooring elements not otherwise provided for
- E04F2290/04—Specially adapted covering, lining or flooring elements not otherwise provided for for insulation or surface protection, e.g. against noise, impact or fire
- E04F2290/045—Specially adapted covering, lining or flooring elements not otherwise provided for for insulation or surface protection, e.g. against noise, impact or fire against fire
Abstract
The invention provides a manufacturing method of a floor structure, which comprises the following steps: providing a wear resistant material comprising at least polyethylene terephthalate; providing a substrate, which at least comprises polyethylene terephthalate and polyethylene; providing an adhesive material which at least comprises polyethylene; and stacking the wear-resistant material and the substrate on two opposite sides of the adhesive material respectively to form a floor structure.
Description
Technical Field
The present invention relates to a method for manufacturing a floor structure, and more particularly, to a method for manufacturing a floor structure made of a polymer.
Background
Conventional plastic floors in the market generally comprise polyvinyl chloride (polyvinyl chloride, PVC) materials. However, polyvinyl chloride is difficult to recycle. In addition, dioxin (or dioxin) is easily generated after combustion of polyvinyl chloride, and serious air pollution is caused.
Disclosure of Invention
The present invention is directed to a method of manufacturing a floor structure having good applicability and/or handleability.
According to an embodiment of the present invention, a method of manufacturing a floor structure includes the steps of: providing a wear resistant material comprising at least polyethylene terephthalate; providing a substrate, which at least comprises polyethylene terephthalate and polyethylene; providing an adhesive material which at least comprises polyethylene; and stacking the wear-resistant material and the substrate on two opposite sides of the adhesive material respectively to form a floor structure.
According to an embodiment of the present invention, the wear-resistant material includes a stack of a plurality of biaxially-oriented polyethylene terephthalate films, and the method for manufacturing the floor structure further includes, before stacking the plurality of biaxially-oriented polyethylene terephthalate films: at least one of the plurality of biaxially-oriented polyethylene terephthalate films is corona treated.
According to an embodiment of the invention, the method of manufacturing a floor structure further comprises the steps of: after corona treatment, at least one of the biaxially stretched polyethylene terephthalate films is coated with a polyurethane glue, a polyester glue, a polymethyl methacrylate glue, or a combination thereof.
According to one embodiment of the present invention, the wear resistant material comprises a biaxially-oriented polyethylene terephthalate film and a laminated film of amorphous polyethylene terephthalate.
According to one embodiment of the invention, the wear resistant material comprises amorphous polyethylene terephthalate.
According to one embodiment of the invention, the wear resistant material is a single amorphous polyethylene terephthalate sheet.
According to an embodiment of the invention, the method of manufacturing a floor structure further comprises the steps of: before the wear-resistant material and the adhesive material are coated, one surface of the wear-resistant material, which is suitable for coating the adhesive material, is subjected to corona treatment, and then a thin layer of polyester, polymethyl methacrylate or polyurethane is formed on the surface subjected to corona treatment in a coating mode.
According to an embodiment of the present invention, the wear-resistant material is an extrusion coated adhesive made of an anhydride modified ethylene copolymer blended polyethylene or ethylene vinyl acetate.
According to an embodiment of the present invention, the wear-resistant material and the adhesive material are laminated in a roll-to-roll manner.
According to an embodiment of the present invention, after stacking the substrate and the adhesive, the rolling step is not performed.
According to an embodiment of the present invention, the step of stacking the wear-resistant material and the substrate on opposite sides of the adhesive material includes: the wear-resistant material and the adhesive material are coated, and then the base material and the adhesive material are stacked.
According to an embodiment of the invention, the method of manufacturing a floor structure further comprises the steps of: before the wear-resistant material and the adhesive material are coated, a pattern layer is formed on one surface of the wear-resistant material or the adhesive material.
According to one embodiment of the invention, the wear-resistant material or substrate is stacked on the adhesive material at least by pressing and heating.
According to an embodiment of the invention, the method of manufacturing a floor structure further comprises the steps of: and forming a balance layer on the lower surface of the substrate layer.
According to one embodiment of the present invention, the floor structure is constructed from materials that do not include polyvinyl chloride.
Based on the above, the manufacturing method of the floor structure can enable the corresponding floor structure to have better applicability and/or handleability.
Drawings
FIG. 1 is a schematic cross-sectional view of a floor structure according to an embodiment of the invention;
FIG. 2 is a schematic illustration of a portion of a method of manufacturing a floor structure according to one embodiment of the invention;
FIG. 3 is a schematic illustration of a portion of a method of manufacturing a floor structure according to an embodiment of the invention;
FIG. 4 is a schematic illustration of a portion of a method of manufacturing a floor structure according to one embodiment of the invention;
FIG. 5 is a schematic illustration of a portion of a method of manufacturing a floor structure according to an embodiment of the invention;
FIG. 6 is a schematic illustration of a portion of a method of manufacturing a floor structure according to an embodiment of the invention;
FIG. 7 is a schematic illustration of a portion of a method of manufacturing a floor structure according to an embodiment of the invention;
fig. 8 is a schematic view of a part of a manufacturing method of a floor structure according to an embodiment of the invention.
Description of the reference numerals
100: a floor structure;
110: a wear-resistant layer;
110a: an upper surface;
110b: a lower surface;
110h: thickness;
120: a subsequent layer;
120a: an upper surface;
120h: thickness;
130: a substrate layer;
130b: a lower surface;
130h: thickness;
140: a pattern layer;
150: a coating layer;
150h: thickness;
160: a balancing layer;
160h: thickness;
200. 300, 400, 500, 600: a compression molding mechanism;
211. 212, 711: a supply roller;
230: a pressure roller wheel;
231: a structural roller;
220: retracting the roller;
240. 740: a glue spreading roller;
250. 750: a die head;
700. 800: a pressure bonding mechanism;
730: a transfer roller;
731: a structural roller;
761. 762: a heating device;
771. 772: a temperature adjustment zone;
881: an upper die;
882: and (5) a lower die.
Detailed Description
Reference will now be made in detail to the exemplary embodiments of the present invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings and the description to refer to the same or like parts.
In the drawings, the size of parts of the components, units and/or assemblies may be exaggerated or reduced for clarity. In addition, some of the components, units, and/or assemblies shown or labeled in the drawings may be omitted for clarity. Also, the numerical values expressed in the specification may include the numerical values as well as deviation values within a deviation range acceptable to those skilled in the art.
Further, relative terms such as "upper" or "lower" may be used herein to describe one component's relationship to another component as illustrated. It will be understood that relative terms are intended to encompass different orientations of the device in addition to the orientation depicted in the figures. For example, if the device in one figure is turned over, elements described as being on the "lower" side of other elements would then be oriented on the "upper" side of the other elements. Thus, the exemplary term "lower" may include both "lower" and "upper" orientations, depending on the particular orientation of the figure. Similarly, if the device in one figure is turned over, elements described as "below" other elements would then be oriented "above" the other elements.
As used herein, "substantially," about "includes both the recited value and an average value within an acceptable deviation of the particular value as determined by one of ordinary skill in the art, which may be expressed in terms of" about the recited value; or, directly in the form of "the value". And, a specific number of measurements and measurement-related errors (i.e., limitations of the measurement system) in question are considered.
Unless defined otherwise, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and the present invention and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
Referring to fig. 1, the floor structure 100 may include a wear layer 110, an adhesion layer 120, and a substrate layer 130.
In one embodiment, the thickness 110h of the wear layer 110 may be about 200 micrometers (μm) to about 1000 μm, and/or the material of the wear layer 110 may include a polymer obtained by reacting a diacid with a diol. Preferably, the wear layer 110 may comprise polyethylene terephthalate (polyethylene terephthalate, PET). For example, the wear layer 110 may include amorphous polyethylene terephthalate (amorphous polyethylene terephthalate, APET), biaxially-oriented polyethylene terephthalate film (Biaxially oriented PET film, BOPET film), or a combination thereof. The amorphous polyethylene terephthalate (APET) and the biaxially-oriented polyethylene terephthalate (BOPET film) can be distinguished at least (but not limited to) by analysis of crystallinity (crystallinity), which is a common knowledge in the related art of polyethylene terephthalate and will not be described herein.
In one embodiment, the wear layer 110 may be a sheet formed solely from amorphous polyethylene terephthalate (APET). In the fabrication of the structure, amorphous polyethylene terephthalate (APET) may be suitable for direct formation of thicker (e.g., 200-1000 microns) films or layers. It is noted that the present invention is not limited to amorphous polyethylene terephthalate (APET) films or layers that are not formed as thin (e.g., less than 200 microns). That is, the amorphous polyethylene terephthalate (APET) is a film or layer that may be less than 200 microns (e.g., less than 150 microns) thick.
In one embodiment, the wear layer 110 may comprise a sheet formed from biaxially-oriented polyethylene terephthalate film (BOPET film). The preparation method may include coating Polyurethane (PU) glue (including the glue and corresponding crosslinking agent), polyester (polyester) glue (including the glue and corresponding crosslinking agent), polymethyl methacrylate (poly (methyl methacrylate), PMMA) glue (including the glue and corresponding crosslinking agent) or a combination thereof on the biaxially stretched polyethylene terephthalate film (BOPET film); then, laminating the composite amorphous polyethylene terephthalate (APET) by an extrusion method. The wear layer 110 may be formed to a predetermined thickness range by the manner described above (e.g., lamination).
In one embodiment, the wear layer 110 may comprise a multi-layer biaxially-oriented polyethylene terephthalate film (BOPET film) that may be bonded by a Polyurethane (PU) adhesive, a polyester (polyester) adhesive, a polymethyl methacrylate (PMMA) adhesive, or a combination thereof. The gum may include solvent-based gum or two-part non-solvent system gum (commonly referred to as AB gum). Before the two biaxially oriented polyethylene terephthalate films (BOPET film) are bonded by the above-mentioned glue, corona treatment (corona) may be performed on the above-mentioned films to make the above-mentioned films have a higher surface tension (for example, greater than or equal to 38dyn/cm, or further greater than or equal to 42 dyn/cm) so as to improve the bonding quality. In the above manner, the wear-resistant layer 110 can be brought into a predetermined thickness range. In the fabrication of structures, biaxially-oriented polyethylene terephthalate films (BOPET film) may be thin (e.g., less than 500 microns; or about 250 microns to 350 microns) and/or may not be formed directly into thicker (e.g., 500 microns to 800 microns) films or layers.
In one embodiment, the wear layer 110 may be made flame retardant during the manufacture of the floor structure 100 or the wear layer 110 by suitable process adjustments (e.g., adding flame retardants or other suitable means). In this context, "flame retardant" means a standard of flame retardancy that can be passed by a standard test means for an object (e.g., a film, layer or structure) being referred to. For example, UL94 plastic flammability standards (Test for Flammability of Plastic Materials for Parts in Devices and appliances) promulgated by underwriter laboratories (Underwriters Laboratories Inc, UL), at least HB rated.
In one embodiment, one of the surfaces (e.g., at least one of the upper surface 110a or the lower surface 110 b) of the wear layer 110 may be non-planar (i.e., non-planar or roughened) by scraping, hot stamping, or matting. Thus, the method can be similar to wood-like lines or extinction surfaces in vision (such as improving the dispersion of reflected light), and can improve the applicability or reduce the visual discomfort; or, in use, the utility model is more antiskid.
The wood-like grain or matt surface formed by ultrasonic embossing or high frequency embossing may be less pronounced than by doctor blading, heat embossing or matting. The production efficiency in the form of laser ablation may be lower than by scraping, embossing or matting.
In one embodiment, the non-planar or rough surface may be formed by a corresponding device (such as a rough roller or an embossing mold), but the present invention is not limited thereto. In one embodiment, the non-planar or rough surface may be formed by the surface of a corresponding film layer (e.g., the adhesive layer 110) during the manufacturing process of the floor structure 100.
In one embodiment, the floor structure 100 may further include a coating layer 150. The coating layer 150 may be located on the upper surface 110a (upper in the drawing) of the wear layer 110. The thickness 150h of the coating layer 150 may be about 5 microns to about 15 microns, and/or the coating layer 150 may include a material that is scratch resistant and/or ultraviolet light absorbing. For example, the material of the coating layer 150 may include polymethyl methacrylate (PMMA). Herein, "scratch resistant" means that the pencil hardness of the object (e.g., film, layer or structure) in question is at least 2H grade. The material of the coating layer 150 may further include a scratch resistant agent, but the present invention is not limited thereto. The scratch resistant agent includes, for example, alumina particles or other suitable hard particles (e.g., pencil hardness of at least 2H).
In one embodiment, the floor structure 100 may further include a pattern layer 140. The pattern layer 140 may be located on the lower surface 110b (lower in the drawing) of the wear layer 110. The pattern layer 140 may be formed on the lower surface 110b of the wear layer 110 by printing (e.g., roll-to-roll printing, gravure printing, screen printing, offset printing, or other suitable printing), transfer printing, or other suitable means. In addition, the pattern layer 140 may partially or completely cover the lower surface 110b of the wear-resistant layer 110 according to the design requirements.
In one embodiment, the lower surface 110b of the wear layer 110 may be corona treated or a thin layer including polyester (polyester), polymethyl methacrylate (PMMA), or Polyurethane (PU) may be formed on the lower surface 110b of the wear layer 110 before the pattern layer 140 is formed on the lower surface 110b of the wear layer 110. In this way, the adhesion between the lower surface 110b of the wear-resistant layer 110 and the pattern layer 140 can be improved.
In one embodiment, the material of the pattern layer 140 may include polyester (polyester), polyethylene terephthalate (PET), polymethyl methacrylate (PMMA), polyurethane (PU), or a combination thereof.
In one embodiment, the thickness 130h of the substrate 130 may be about 3 millimeters (mm) to about 5 mm, and/or the material of the substrate 130 may include inorganic materials and polymers. For example, inorganic materials may be added to a polymer feedstock (e.g., polymer chips) and extruded (extrusion process) to form a suitable material for the wear layer 110. In the material for the substrate layer 130, the weight ratio of the inorganic material is about 70wt% to 30wt% and the weight ratio of the polymer is about 30wt% to 70wt% based on the weight of a specific unit.
In one embodiment, the extrusion process suitable for the substrate layer 130 may include the following steps: first, the following first stage: providing an extrusion device (such as a single screw extruder (single screw extruder) or a twin screw extruder (twin screw extruder)) to mix the inorganic material and the polymer raw material into the extrusion device (such as feeding through a feed port (feeder) of the extruder) and then performing dehumidification drying at a temperature ranging from about 100 ℃ to 120 ℃; then, mixing and granulating the mixture through an extruder at a temperature ranging from about 265 ℃ to 290 ℃; thereafter, a second stage is as follows: drying the polymer pellets (polymer chips) in a temperature range of about 100 ℃ to 120 ℃; the molding is then extruded through a die, such as a T-die, at a temperature in the range of about 150℃to 195℃by a similar extrusion apparatus.
In one embodiment, among the polymers used in the substrate layer 130, there may be included, for example: polyethylene (PE), polyethylene terephthalate (PET), or a combination thereof. Also, the polymer feedstock used may include virgin polymer pellets (virgin polymer chip), recycled polymer pellets (recycled polymer chip), or a combination thereof. In one embodiment, the weight ratio of Polyethylene (PE) to polyethylene terephthalate (PET) in the polymer material used for the substrate layer 130 may be about 1:1 to about 1:2 (may include an equivalent range of about.+ -. 10%).
In one embodiment, the inorganic material used in the material of the substrate layer 130 may include heat resistance or thermal stability (e.g. no natural gas or combustion gas is generated after heating), high hardness (e.g. Vickers Hardnesses (VH) of more than 100), and low hydrolyzability (e.g. solubility product (solubility product, ksp) of less than 1×10) -6 ) Inorganic particles or inorganic salts thereof. For example, the inorganic material used in the material of the substrate layer 130 may include calcium carbonate powder or particles, silica powder or particles, glass fiber, or a combination thereof.
In one embodiment, the substrate layer 130 may be the thickest layer of the floor structure 100; therefore, the inorganic material is added in an amount of 30wt% to 70wt% to the material of the substrate layer 130, so that the floor structure 100 has better flame retardance, can bear better external stress and/or can reduce the dosage of the polymer (such as Polyethylene (PE) or polyethylene terephthalate (PET)). In addition, since the substrate layer 130 may be the thickest layer in the floor structure 100; thus, recycling of recycled material in the flooring structure 100 may be enhanced by forming the substrate layer 130 from recycled polymer, such as by pelletizing recycled Polyethylene (PE) or polyethylene terephthalate (PET), for recycling economy.
In one embodiment, the floor structure 100 may further include a balancing layer 160. The balancing layer 160 may be the bottom most or the layer furthest from the user's accessible surface in the floor structure 100. For example, the balance layer 160 may be located on the lower surface 130b (lower in the drawing) of the substrate layer 130.
In one embodiment, the thickness 160h of the balancing layer 160 may be about 1000 microns to about 2000 microns, and/or the balancing layer 160 may include a porous membrane layer formed by physical foaming or chemical foaming. For example, the material of the balancing layer 160 may include ethylene vinyl acetate (ethylene vinyl acetate, EVA), polyethylene (PE), cross-linked polyethylene (irradiation cross-linked polyethylene, IXPE), or a combination thereof. Also, in the process of forming the balance layer 160, a porous film layer may be formed by addition of a gas or a foaming agent. By balancing the porous nature of the layer 160, the floor structure 100 may have better applicability (e.g., easier application to the ground and/or providing corresponding cushioning).
In the present embodiment, the adhesion layer 120 is located between the wear-resistant layer 110 and the substrate layer 130, so that the wear-resistant layer 110 and the substrate layer 130 can be directly or indirectly connected to each other through the adhesion layer 120 located therebetween.
In one embodiment, the thickness 120h of the adhesion layer 120 may be about 30 μm to 100 μm, and/or the adhesion layer 120 may be made of Polyethylene (PE). For example, the polyethylene for the adhesive layer 120 may include high-density polyethylene (HDPE), low-density polyethylene (LDPE) and linear low-density polyethylene (LLDPE). Preferably, the polyethylene used for the adhesive layer 120 is Low Density Polyethylene (LDPE), linear Low Density Polyethylene (LLDPE), or a combination thereof.
In one embodiment, the adhesive layer 120 may be a single polyethylene film layer.
In one embodiment, the material of the adhesive layer 120 may include polyethylene. For example, in terms of processing, a suitable adhesive layer (e.g., polyurethane (PU) adhesive (which may include the foregoing adhesive and corresponding crosslinking agent), polyester (polyester) adhesive (which may include the foregoing adhesive and corresponding crosslinking agent), polymethyl methacrylate (PMMA) adhesive (which may include the foregoing adhesive and corresponding crosslinking agent), or a combination thereof) may be coated on one side of the solid film (which is a polyethylene terephthalate (PET) material), and the polyethylene is extruded into a liquid state or laminated with a 30-70 μm film to form the corresponding adhesive layer 120. The gum may include a solvent-based gum or a two-part non-solvent-based gum. In the adhesive layer 120 correspondingly formed in the manner described above, the polyethylene material may be adapted to bond with the substrate layer 130 (which includes at least Polyethylene (PE) and polyethylene terephthalate (PET)) such as to heat and melt the Polyethylene (PE) therein, and the adhesive layer may be adapted to bond with the wear-resistant layer 110.
In one embodiment, during the manufacturing process of the floor structure 100, the wear-resistant layer 110 and the substrate layer 130 may be formed in different steps; the wear-resistant layer 110 and the Polyethylene (PE) in the substrate layer 130 can then be connected to each other by an adhesive layer 120 formed of at least Polyethylene (PE). Also, since the abrasion-resistant layer 110 or the substrate layer 130 formed of the same or similar polyester (polyester) or polyethylene terephthalate (PET) material has a substantially fixed structure after being formed (e.g., it may be difficult to soften or flow again after reheating), the abrasion-resistant layer 110 and the substrate layer 130 can be easily connected to each other by the adhesion layer 120 formed of at least Polyethylene (PE) material, and structural delamination (structure peeling) of the floor structure 100 can be reduced to improve the quality of the floor structure 100.
In one embodiment, the material of the adhesive layer 120 may further include a coloring material. For example, a corresponding colorant may be added during the fabrication process of the adhesive layer 120 (e.g., during the heat softening process of polyethylene). The color of the colorant can be selected according to the need. For example, white titanium dioxide (often referred to as titanium dioxide) may be added. In one embodiment, the substrate layer 130 formed by recycling the polymer particles may be visually less attractive (e.g., yellowing); therefore, the adhesive layer 120 containing the coloring material can mask the corresponding substrate layer 130 to improve the overall visual quality of the floor structure 100.
In one embodiment, the weight ratio of colorant in the material used for the adhesive layer 120 is about 0.01wt% to about 3wt% based on the weight of a particular unit. If the proportion of the coloring material is too high (e.g., more than 3 wt%), the bonding of the adhesive layer 120 to other film layers may be affected.
In an embodiment, the pattern layer 140 may also be formed on the upper surface 120a (upper in the drawing) of the adhesion layer 120.
In one embodiment, the material used for each layer or film in the floor structure 100 may not include plant fiber material. The aforementioned plant fiber materials include, but are not limited to: wood materials such as wood fiber, wood dust, or cotton materials such as cotton fiber. In this way, the fire retarding capabilities of the floor structure 100 may be improved.
In one embodiment, the materials used for each layer or film in the floor structure 100 may be added or include a flame retardant. The material used for each layer or film in the floor structure 100 is essentially a polymer, and therefore, the flame retardant is preferably an organic flame retardant. More preferably, the flame retardant is an organic phosphorus flame retardant. In this way, the fire retarding capabilities of the floor structure 100 may be improved. The aforementioned organic phosphorus-based flame retardant may include, but is not limited to: [ (6-oxo-6H-dibenzo [ C, E ] [1,2] oxaphosphorin-6-yl) methyl ] butanedioic acid bis (2-hydroxyethyl) ester ([ (6-oxo-6H-dibenzo [ C, E ] [1,2] oxaphosporin-6-yl) methyl ] butanedioic acid bis (2-hydroxyyethyl) ester; CAS number 63562-34-5), [ (6-oxo-6H-dibenzo [ C, E ] [1,2] oxaphospha-hex-6-yl) methyl ] butanedioic acid ([ (6-Oxido-6H-dibenzo [ C, E ] [1,2] oxa-6-yl) methyl ] butanedioic acid; CAS number 63562-33-4), 10-benzyl-9-oxa-10-phospha-10-oxide (10-benzylmethyl-9-oxa-10-phosphaphe nanthrene-10-oxide; CAS number 113504-81-7), bis (4-hydroxybutyl) 2- [ (9, 10-dihydro-9-oxa-10-yl) butanedioic acid ] methyl ester (4-hydroxybutyl) 2- [ (9, 10-dihydro-9-oxa-10-yl) butanedioic acid (CAS number 63562-33-4), 10-oxa-10-phospha-10-oxa-10-yl) 2- [ (9, 10-hydroxy-oxa-10-methyl) 2] butan-10-oxide (CAS number 113504-81-7), bis (4-hydroxybutyl) 2- [ (9, 10-dioxa-10-yl) butanedio-acid ] methyl ester (CAS number 1-18-oxa-10-yl) 2 2-carboxyethylphenyl hypophosphorous acid (2-carboxyethyl (phenyl) phosphinic acid; CAS number 14657-64-8), 6'- (1-phenylethane-1, 2-diyl) bis (6H-dibenzo [ c, e ] [1,2] oxaphosphorinane) 6,6' -dioxide (6, 6'- (1-phenylethane-1, 2-diyl) bis (6H-dibenzo [ c, e ] [1,2] oxaphos-bin) 6,6' -dioxide; CAS number 1631149-46-6), or combinations thereof.
In one embodiment, the materials used for each layer or film (e.g., the adhesive layer 120 and/or the substrate layer 130) in the floor structure 100 may not include polyvinyl chloride based on recycling, waste disposal, and/or environmental friendliness (eco-friendly) of the floor structure 100 after use. Further, since the material used for at least one layer or film (e.g., the adhesive layer 120) in the floor structure 100 includes Polyethylene (PE), the material used for each layer or film in the floor structure 100 does not include halogen, so as to reduce the possibility of dioxin generation during waste treatment (e.g., combustion) of the floor structure 100 after use.
In a simple manner, the materials forming the layers may be stacked to form a floor structure that is the same as or similar to one of the embodiments described above. For example: materials that can be used to form the wear resistant layer can be referred to as wear resistant materials, materials that can be used to form the adhesion layer can be referred to as adhesion materials, materials that can be used to form the substrate layer can be referred to as substrates, materials that can be used to form the coating layer can be referred to as coating materials, and the like.
The following describes a part of the manufacturing method of a floor structure according to an embodiment of the present invention in detail. It should be noted that the floor structure according to one of the embodiments of the present invention can be manufactured by the following method, but is not limited thereto; alternatively, a method of manufacturing a floor structure as described below may be used to manufacture a floor structure identical or similar to one of the above embodiments, but is not limited thereto.
Fig. 2 is a schematic view of a part of a manufacturing method of a floor structure according to an embodiment of the invention. In particular, the manufacturing method shown in FIG. 2 may be suitable for the manufacture of wear layers (e.g., the same or similar to the wear layer 110 described above).
Referring to fig. 2, a compression molding mechanism 200 is provided. The compression molding mechanism 200 may include a plurality of rollers. The plurality of rollers includes a supply roller 211, a pressing roller 230, and a recovery roller 220. The supply roller 211 is adapted for supply of a film or layer, the recovery roller 220 is adapted for take-up of a film or layer, and the pressure roller 230 is adapted for pressurizing the film or layer on a conveying path of the film or layer. The film or layer transport path, the rotational speed of each roller and/or the number of pressure rollers 230 may be adaptively adjusted according to design requirements. The operation of the compression molding mechanism 200 and/or its rollers may be the same or similar to a similar roll-to-roll mechanism (roll-to-roll mechanism), and therefore will not be described in detail herein.
Referring to fig. 2, the supply roller 211 is suitable for supplying polyethylene terephthalate (PET) material in a film form (film), which may be biaxially stretched polyethylene terephthalate film (BOPET film). And, a polyethylene terephthalate (PET) material may be extruded through a die 250, such as a T-die or an extruder outlet die, and coated on one surface of the film-shaped polyethylene terephthalate (PET) material, and may be laminated or compacted by a subsequent pressing roller 230. The thickness of the sheet-like (sheet) polyethylene terephthalate (PET) material, such as a sheet formed from amorphous polyethylene terephthalate (APET), can be up to 1000 microns, and thus does not have to be thickened in the manner described above.
In one embodiment, a suitable primer may be added to the polyethylene terephthalate (PET) material supplied by the supply roller 211, which may include a surface modifying agent and/or an adhesion treating agent pre-coated on the surface thereof. The treating agent may include, for example, a polymethyl methacrylate (poly (methyl methacrylate), PMMA) treating agent, a polyurethane composite acryl treating agent, a polyester (polyester) treating agent, a polyester composite polyurethane treating agent, or a combination of the above. The aforementioned treatment agents may be commercially available. The aforementioned treatment agents may include corresponding crosslinking agents, such as: an aziridine crosslinking agent, an oxazoline crosslinking agent, a melamine crosslinking agent, an isocyanate crosslinking agent, an oxazoline crosslinking agent, or an isocyanate crosslinking agent.
Referring to fig. 2, before extruding a polyethylene terephthalate (PET) material and covering a surface of the sheet-like or film-like PET material, a corresponding adhesive layer may be formed on the surface to be covered. The glue layer (e.g., the aforementioned resin glue layer) may be formed, for example, by a corresponding coating device (e.g., glue roll 240; but not limited thereto).
In the above manner, the wear-resistant layer may be formed and may be brought to a predetermined thickness range and/or may be provided with appropriate texturing. The depth of the texture may be about 50 microns to 200 microns. For example, the film or layer wound up by the take-up roller 220 may be considered or used as an abrasion resistant layer after being properly processed (e.g., cut); or may be directly considered or used as a wear layer.
Fig. 3 is a schematic view of a part of a manufacturing method of a floor structure according to an embodiment of the invention. In particular, the manufacturing method shown in FIG. 3 may be suitable for the manufacture of wear layers (e.g., the same or similar to the wear layer 100 described above).
Referring to fig. 3, a press forming mechanism 300 is provided, which may be similar to the press forming mechanism 200 (shown in fig. 2) described above, and thus will not be described herein.
Referring to fig. 3, a biaxially-oriented polyethylene terephthalate film (BOPET film) is fed by a feeding roller 211, and another biaxially-oriented polyethylene terephthalate film (BOPET film) is fed by another feeding roller 212. After the two films are laminated, the laminated film may be pressed or compacted by a subsequent pressing roller 230.
Referring to fig. 3, before the two films are laminated, a corresponding adhesive layer may be formed on the surface to be stacked (at least one of the two films may be formed). The glue layer may be formed, for example, by a corresponding coating device (e.g., glue roll 240; but not limited to).
It should be noted that, based on the material properties of polyethylene terephthalate, if two film-coating films (including but not limited to film-coating and glue-bonding) as shown in fig. 3 are to be adopted, it is more suitable to adopt biaxially-oriented polyethylene terephthalate film (BOPET film), but may not be suitable for non-crystallized polyethylene terephthalate (APET), and the possible reasons are that: in the process of laminating the amorphous polyethylene terephthalate, whitening phenomenon may occur due to recrystallization.
In the above manner, the wear-resistant layer can be formed, and the wear-resistant layer can be brought into a predetermined thickness range. For example, the film or layer wound up by the take-up roller 220 may be considered or used as an abrasion resistant layer after being properly processed (e.g., cut); or may be directly considered or used as a wear layer.
The film or layer wound up by the retraction roller 220 can be embossed appropriately so that at least one surface of the wear-resistant layer is not planar or has corresponding texture; this may be referred to as off-line embossing. However, if off-line embossing is to be used (as shown in fig. 8 described later), it may be suitable to use biaxially-oriented polyethylene terephthalate film (BOPET film), but it may not be suitable for amorphous polyethylene terephthalate (APET), possibly because: the amorphous polyethylene terephthalate (APET) may need to be softened by reheating during pressing and/or may be whitened by recrystallization.
In addition, because the texture of the coating layer is harder (compared to the wear layer), it may be less suitable to form on the wear layer prior to rolling. The reason is that: if a coating layer (e.g., the same or similar to the coating layers described above) is formed on the wear layer prior to rolling, the coating layer may have cracks during or after rolling. That is, if the floor structure is manufactured by a reel-to-reel mechanism, basically no reeling step is performed after the coating layer is formed (but other steps such as washing, drying, cutting or edging may be performed).
Fig. 4 is a schematic view of a part of a manufacturing method of a floor structure according to an embodiment of the invention. Specifically, the fabrication method shown in FIG. 4 may be adapted for fabrication of an adhesion layer (e.g., the same or similar to the adhesion layer 120 described above).
Referring to fig. 4, a press forming mechanism 400 is provided, which may be similar to the press forming mechanism 200 (shown in fig. 2) described above, and thus will not be described herein.
Referring to FIG. 4, the supply roller 211 is suitable for supplying a sheet or film of polyethylene terephthalate (PET) (which may be referred to as a wear-resistant layer), such as a sheet or biaxially-oriented polyethylene terephthalate film (BOPET) formed from the amorphous polyethylene terephthalate (APET) produced in the manner described above (e.g., FIG. 2 or FIG. 3). And, a Polyethylene (PE) material may be extruded through a die 250 (e.g., T-die) and laminated on one surface of the sheet-shaped or film-shaped polyethylene terephthalate (PET) material, and may be laminated or compacted (compacted) by a subsequent pressing roller 230.
Referring to fig. 4, before extruding and laminating a Polyethylene (PE) material on a surface of the sheet-like or film-like polyethylene terephthalate (PET) material, a corresponding adhesive layer may be formed on the surface to be laminated. The glue layer may be formed by, for example, applying glue by a corresponding applicator (such as glue roller 240; but not limited to).
In the above manner, the adhesive layer on the abrasion-resistant layer can be formed, and the adhesive layer can be brought to a predetermined thickness range. For example, the film or layer rolled up by the take-up roller 220 may be considered or used as a wear layer and an adhesive layer after being properly processed (e.g., cut); alternatively, it can be directly considered or used as the abrasion-resistant layer and the adhesive layer.
In the process of forming or manufacturing the wear-resistant layer (as shown in fig. 2), the surface of the wear-resistant layer may be formed to be different from a plane or have a corresponding texture by adjusting the texture on the surface of a roller (e.g., the structural roller 231, which may be one of the pressing rollers 230); this manner of dynamic movement of the embossed object in the non-embossing direction during the embossing process may be referred to as: in-line embossing. In-line embossing may be suitable for use with non-crystallizing polyethylene terephthalate (APET) sheets. The structural roller 231 is basically at least one of the roller sets of the first set corresponding to the die 250 after extruding the material, and other rollers may not be able to serve as the structural rollers.
Fig. 5 is a schematic view of a part of a manufacturing method of a floor structure according to an embodiment of the invention. Specifically, the fabrication method shown in FIG. 5 may be adapted for fabrication of an adhesion layer (e.g., the same or similar to the adhesion layer 120 described above).
Referring to fig. 5, a press forming mechanism 500 is provided, which may be similar to the press forming mechanism 200 (shown in fig. 2) described above, and thus will not be described herein.
Referring to FIG. 5, a sheet or biaxially oriented polyethylene terephthalate (BOPET) film of amorphous polyethylene terephthalate (APET) produced as described above (e.g., FIG. 2 or FIG. 3) is suitably fed by a feeding roller 211. And, the other supply roller 212 is adapted to supply a Polyethylene (PE) material in a sheet or film form, which may be a polyethylene film (PE film) having a thickness of about 30 micrometers to 100 micrometers. After the two films are laminated, the laminated film may be pressed or compacted by a subsequent pressing roller 230.
It is noted that two film coatings may be applied in the manner described above based on the material properties of polyethylene terephthalate (PET) and Polyethylene (PE). The reason is that: thermoplastic polyethylene films (PE) are softer in texture (e.g., small Young's modulus) and/or more plastic when heated (e.g., laminated or compacted). Therefore, even when amorphous polyethylene terephthalate (APET) is used, it is substantially difficult or impossible to recrystallize the polyethylene terephthalate to cause whitening.
Referring to fig. 5, before the two films are laminated, a corresponding adhesive layer may be formed on the surface (at least one of the two films) to be laminated. The glue layer may be formed by, for example, applying glue by a corresponding applicator (such as glue roller 240; but not limited to).
In the above manner, the adhesive layer on the abrasion-resistant layer can be formed, and the adhesive layer can be brought to a predetermined thickness range. For example, the film or layer rolled up by the take-up roller 220 may be considered or used as a wear layer and an adhesive layer after being properly processed (e.g., cut); alternatively, it can be directly considered or used as the abrasion-resistant layer and the adhesive layer.
In the manner described in fig. 4 and/or fig. 5, since the Polyethylene (PE) and the polyethylene terephthalate (PET) are mixed to form the adhesive layer, the polyethylene terephthalate (PET) in the form of a sheet or film is used, the adhesive used is basically a solvent-based adhesive (such as Polyurethane (PU) adhesive, reactive polyurethane adhesive (polyurethane reactive; PUR) adhesive (which may include the foregoing adhesive and the corresponding crosslinking agent), polymethyl methacrylate (PMMA) adhesive (which may include the foregoing adhesive and the corresponding crosslinking agent), or a combination thereof.
Fig. 6 is a schematic view of a part of a manufacturing method of a floor structure according to an embodiment of the invention. Specifically, the fabrication method shown in FIG. 6 may be adapted for fabrication of an adhesion layer (e.g., the same or similar to the adhesion layer 120 described above).
Referring to fig. 6, a press forming mechanism 600 is provided, which may be similar to the press forming mechanism 200 (shown in fig. 2) described above, and thus will not be described herein.
Referring to FIG. 6, a sheet or biaxially oriented polyethylene terephthalate (BOPET) film of amorphous polyethylene terephthalate (APET) produced as described above (e.g., FIG. 2 or FIG. 3) is suitably fed by a feeding roller 211. And, the material containing at least Polyethylene (PE) may be pressed out through a die 250 (e.g., T-die) and coated on one surface of the sheet-shaped or film-shaped polyethylene terephthalate (PET) material, and may be laminated or compacted (compacted) by a subsequent pressing roller 230.
In one embodiment, a blend of Polyethylene (PE) and other materials, which may be referred to as a modified ethylene copolymer (modified ethylene copolymer), may be extruded through a die 250. For example, a blend of Polyethylene (PE), ethylene Vinyl Acetate (EVA) and anhydride (which may be referred to as an anhydride-modified ethylene copolymer (anhydride modified ethylene copolymer), one of which may be referred to as a modified polyethylene) may be extruded through die 250. Generally, the Polyethylene (PE) material is nonpolar and the polyethylene terephthalate (PET) material is polar, so that the Polyethylene (PE) and the polyethylene terephthalate (PET) material cannot be directly bonded or are difficult to directly bond, and the Polyethylene (PE) and the polyethylene terephthalate (PET) material can be bonded by modifying the ethylene copolymer by the anhydride with both polar and nonpolar functional groups.
In the manner described in fig. 6, a solvent such as an organic solvent such as diethyl ether (DEE), acetone (DMK), dichloromethane (DCM), chloroform (TCM), 1,2-dichloroethane (1, 2-dichloroethane, DCE), methanol (MeOH), ethanol (EtOH), tetrahydrofuran (THF), ethyl Acetate (EA), acetonitrile (CAN), ethylene glycol dimethyl ether (DME), benzene (benzene), toluene (toluene), xylene (xylene), pyridine (pyridine), dimethylformamide (DMF), dimethyl sulfoxide (DMSO) or the like may be substantially not used in forming the adhesive layer.
In the above manner, the adhesive layer on the abrasion-resistant layer can be formed, and the adhesive layer can be brought to a predetermined thickness range. For example, the film or layer rolled up by the take-up roller 220 may be considered or used as a wear layer and an adhesive layer after being properly processed (e.g., cut); alternatively, it can be directly considered or used as the abrasion-resistant layer and the adhesive layer.
Fig. 7 is a schematic view of a part of a manufacturing method of a floor structure according to an embodiment of the invention. In particular, the manufacturing method shown in fig. 7 may be applied to layer-to-layer bonding. For example, the manufacturing method shown in fig. 7 may be applied to bonding the adhesion layer on the wear-resistant layer to the substrate layer.
Referring to fig. 7, a press-bonding mechanism 700 is provided. The press-bonding mechanism may include a plurality of rollers. The plurality of rollers includes a supply roller 711 and a transfer roller 730. The supply roller 711 is adapted for supply of a film or layer, and the transfer roller 730 is adapted for transfer of the film or layer on a transfer path of the film or layer. The film or layer transfer path, the rotational speed of each roller, and/or the number of transfer rollers 730 may be adaptively adjusted according to design requirements. In addition, for clarity, not all of the transfer rollers 730 are labeled one by one in fig. 7. One of the transfer rollers 730 may be used for pressurization and may be referred to as a pressurization roller. The texture on the surface of one of the transfer rollers 730 (e.g., the form roller 731) may be used to emboss the surface of the film or layer with a corresponding structure, referred to as a form roller. The structural roller 731 is basically at least one of the roller sets of the first set corresponding to the feeding roller 711 after feeding the material, and other rollers may not be able to serve as the structural roller. One of the transfer rollers 730 may be coupled to a heating device and may be referred to as a heating roller. One of the transfer rollers 730 may be coupled to a cooling device and may be referred to as a cooling roller. The pressure bonding mechanism 700 and/or its rollers may operate in the same or similar manner as a similar roll-to-roll mechanism (roll-to-roll mechanism), and therefore will not be described in detail herein.
Referring to FIG. 7, the supply roller 711 is adapted to supply a roll of material, such as that described above (e.g., any of FIGS. 4-6). Further, before bonding the web to other films or layers (e.g., sheet-like or film-like polyethylene terephthalate (PET) materials described below), a portion of the material (e.g., polyethylene (PE)) in the web may be softened by a heating device 761 and then adapted for bonding in a subsequent step.
With continued reference to FIG. 7, a film-like polyethylene terephthalate (PET) material (which may be considered as an abrasion resistant layer; or a film layer that is further laminated with an adhesive layer) is provided, which may be a sheet of amorphous polyethylene terephthalate (APET), a biaxially-oriented polyethylene terephthalate film (BOPET) or a stack of one or more of the foregoing, and may be provided by another supply roll (not shown) or extruded directly through a die 750, such as a T-die (T-die). In one embodiment, the film-like polyethylene terephthalate (PET) material may be heated by the heating device 762 before being bonded to other films or layers (e.g., the aforementioned roll material), but the invention is not limited thereto.
With continued reference to fig. 7, the web is bonded to the sheet-like or film-like polyethylene terephthalate (PET) material. Suitable places for performing the aforementioned bonding step may be within a temperature adjustment zone 771.
With continued reference to fig. 7, after the web is bonded to the sheet-like or film-like polyethylene terephthalate (PET) material, the bonded film layer may be passed through a temperature adjustment zone 772. The temperature adjustment area may have a corresponding temperature adjustment means (e.g., a means for supplying cooling water or cooling gas, or a means for supplying hot water) within the range of the temperature adjustment area, but the present invention is not limited thereto.
With continued reference to fig. 7, after the roll is bonded to the sheet-like or film-like polyethylene terephthalate (PET) material, a coating device (e.g., a glue roller 740) may be used to coat or form a corresponding film layer (e.g., a coating layer 150) at a suitable location and/or add a suitable material (e.g., particles and UV absorber, which may have a thickness of 5-15 μm) and press the film layer.
With continued reference to fig. 7, after the web is bonded to the sheet or film of polyethylene terephthalate (PET), additional layers may be further formed or bonded in a manner similar to that shown in fig. 7.
In one embodiment, the same or similar dynamic bonding (i.e., the bonded object is still dynamically moving in the non-bonding direction during bonding) as shown in FIG. 7 can be: on-line (in-line) bonding.
In the process of online (in-line) bonding, embossing needs to be softened by a substrate layer at 120-170 ℃, polyethylene (PE) is thoroughly pressed to the substrate layer by a wear-resistant layer heating and pressurizing mode, a structural roller 731 modeling wheel is used for forming when single amorphous polyethylene terephthalate (APET) is formed or laminated amorphous polyethylene terephthalate (APET) is thickened, the temperature of the roller is maintained at about 60-75 ℃ in order to avoid flattening when the embossing is bonded with the substrate layer, and the temperature of the substrate layer is controlled at about 150-170 ℃. The biaxially stretched polyethylene terephthalate (BOPET) is hard because of its high crystallinity, and therefore, the film is heated to 150-170 ℃ and the substrate layer is heated to 120-170 ℃ to soften the Polyethylene (PE), and the Polyethylene (PE) is softened by the substrate layer, so that the wear-resistant layer is heated and pressed to the substrate layer to form the texture (e.g. by the shaping wheel of the structural roller 731. The embossing depth of the amorphous polyethylene terephthalate (APET) or biaxially-oriented polyethylene terephthalate (BOPET) may be about 50 microns to 200 microns. While the temperature of the substrate layer is 120-170 ℃, the polyethylene terephthalate (PET) can still be maintained in a solid state.
In the manner described above, a floor structure (e.g., the same or similar to the floor structure 100 described above) may be formed. For example, the bonded structure may be considered or used as a flooring structure after suitable processing (e.g., re-forming the same or similar to the coating layer 150, the same or similar to the balancing layer 160, or other suitable film layers, cutting, polishing, and/or edging) as described above; alternatively, it may be considered directly or as a floor structure.
Fig. 8 is a schematic view of a part of a manufacturing method of a floor structure according to an embodiment of the invention. In particular, the manufacturing method shown in fig. 8 may be applied to layer-to-layer bonding. For example, the manufacturing method shown in fig. 8 may be applied to bonding the adhesion layer on the abrasion-resistant layer to the substrate layer.
Referring to fig. 8, a press-bonding mechanism 800 is provided. The press-bonding mechanism may include an upper die 881 (upper in the drawing) and a lower die 882 (lower in the drawing). The objects to be press-bonded may be placed between the upper die 881 and the lower die 882 to be press-bonded. For example, a sheet (e.g., a roll of material as shown in FIGS. 4-6, which is then suitably cut) and a sheet or film of polyethylene terephthalate (PET) material may be placed between the upper and lower molds for bonding. For example, as shown in fig. 8, a layer 891 therebetween may be the same as or similar to the abrasion resistant layer 110 described above, a layer 892 therebetween may be the same as or similar to the adhesive layer 120 described above, and/or a layer 893 therebetween may be the same as or similar to the substrate layer 130 described above.
In the present embodiment, at least one of the upper mold 881 or the lower mold 882 may be coupled to a heating device to improve the bonding quality during the press bonding process, but the present invention is not limited thereto. In one embodiment, the temperature of the upper die 881 or the lower die 882 may be between 120 ℃ and 170 ℃ during the press bonding process.
After bonding the sheet material to the sheet or film-like polyethylene terephthalate (PET) material and cooling for a suitable time, the bonded material may be taken out and coated or formed into a corresponding film layer at a suitable position by a coating device (not shown); alternatively, other layers may be further formed or bonded in a manner similar to that shown in FIG. 8.
In one embodiment, the upper die 881 or lower die 882 may have appropriate embossments on its pressurized surface. Therefore, the pressed film layer can have corresponding lines. Taking fig. 8 as an example, the upper die 881 may have appropriate embossments on its pressing surface.
In one embodiment, the pressing surface of the upper mold 881 or the lower mold 882 may be covered with a release film (e.g., mylar film or silane-or fluorine-coated release film) which may allow the bonded article to be easily released from the corresponding mold.
In one embodiment, the same or similar static bonding (i.e., the bonded object does not substantially move in the non-bonding direction during bonding) as shown in FIG. 8 may be: off-line (off-line) bonding. The off-line bonding approach is more suitable for biaxially-oriented polyethylene terephthalate film (BOPET film), but may not be suitable for amorphous polyethylene terephthalate (APET), possibly due to: the non-crystallized polyethylene terephthalate may be whitened by recrystallization during the heating lamination.
In the above manner, a floor structure can be formed. For example, the structure after bonding may be considered or used as a flooring structure after appropriate processing (e.g., cutting, polishing, and/or edging); alternatively, it may be considered directly or as a floor structure.
In summary, the above-described manufacturing method according to the present invention can be suitably used for manufacturing the floor structure according to the present invention. And, the floor structure of the present invention is superior in applicability and/or handleability.
Finally, it should be noted that: the above embodiments are only for illustrating the technical solution of the present invention, and not for limiting the same; although the invention has been described in detail with reference to the foregoing embodiments, it will be understood by those of ordinary skill in the art that: the technical scheme described in the foregoing embodiments can be modified or some or all of the technical features thereof can be replaced by equivalents; such modifications and substitutions do not depart from the spirit of the invention.
Claims (15)
1. A method of manufacturing a floor structure, comprising:
providing a wear resistant material comprising at least polyethylene terephthalate;
providing a substrate, which at least comprises polyethylene terephthalate and polyethylene;
providing an adhesive material which at least comprises polyethylene; and
and stacking the wear-resistant material and the base material on two opposite sides of the adhesive material respectively to form the floor structure.
2. The method of manufacturing a floor structure according to claim 1, wherein the wear resistant material comprises a stack of a plurality of biaxially-oriented polyethylene terephthalate films, and the method of manufacturing a floor structure further comprises, prior to stacking the plurality of biaxially-oriented polyethylene terephthalate films: at least one of the plurality of biaxially-oriented polyethylene terephthalate films is corona treated.
3. The method of manufacturing a floor structure according to claim 2, further comprising: after the corona treatment, at least one of the plurality of biaxially-oriented polyethylene terephthalate films is coated with a polyurethane-based adhesive, a polyester-based adhesive, a polymethyl methacrylate-based adhesive, or a combination thereof.
4. The method of manufacturing a floor structure according to claim 1, wherein the abrasion resistant material comprises a biaxially-oriented polyethylene terephthalate film and a laminated film of amorphous polyethylene terephthalate.
5. The method of manufacturing a floor structure according to claim 1, wherein the wear resistant material comprises non-crystallizing polyethylene terephthalate.
6. The method of manufacturing a floor structure according to claim 5, wherein the wear-resistant material is a single amorphous polyethylene terephthalate sheet.
7. The method of manufacturing a floor structure according to claim 1, further comprising: before the wear-resistant material and the adhesive material are coated, one surface of the wear-resistant material, which is suitable for coating the adhesive material, is subjected to corona treatment, and then a thin layer of polyester, polymethyl methacrylate or polyurethane is formed on the surface subjected to corona treatment in a coating mode.
8. The method of manufacturing a floor structure according to claim 1, wherein the abrasion-resistant material is the adhesive material laminated by extrusion of an acid anhydride modified ethylene copolymer blended polyethylene or ethylene vinyl acetate.
9. The method of manufacturing a floor structure according to claim 1, wherein the wear-resistant material and the adhesive material are laminated in a roll-to-roll manner.
10. The method of claim 9, wherein the step of winding up is not performed after stacking the substrate and the adhesive.
11. The method of manufacturing a floor structure according to claim 9, wherein the step of stacking the wear-resistant material and the base material on opposite sides of the adhesive material, respectively, comprises:
and firstly, laminating the wear-resistant material and the adhesive material, and then stacking the substrate and the adhesive material.
12. The method of manufacturing a floor structure according to claim 1, further comprising:
and forming a pattern layer on one surface of the wear-resistant material or the adhesive material before the wear-resistant material and the adhesive material are subjected to film coating.
13. The method of manufacturing a floor structure according to claim 1, wherein the wear-resistant material or the base material is stacked on the adhesive material at least by pressing and heating.
14. The method of manufacturing a floor structure according to claim 1, further comprising:
And forming a balance layer on the lower surface of the substrate layer.
15. The method of manufacturing a floor structure according to claim 1, wherein all materials in the floor structure are composed excluding polyvinyl chloride.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| TW111113014 | 2022-04-06 | ||
| TW111113014A TW202339967A (en) | 2022-04-06 | 2022-04-06 | Manufacturing method of floor structure |
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| Publication Number | Publication Date |
|---|---|
| CN116922906A true CN116922906A (en) | 2023-10-24 |
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202210519856.4A Pending CN116922906A (en) | 2022-04-06 | 2022-05-13 | Method for manufacturing floor structure |
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|---|---|
| CN (1) | CN116922906A (en) |
| TW (1) | TW202339967A (en) |
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- 2022-04-06 TW TW111113014A patent/TW202339967A/en unknown
- 2022-05-13 CN CN202210519856.4A patent/CN116922906A/en active Pending
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