CN214220433U - 一种聚氨酯复合地板 - Google Patents

一种聚氨酯复合地板 Download PDF

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CN214220433U
CN214220433U CN202020832278.6U CN202020832278U CN214220433U CN 214220433 U CN214220433 U CN 214220433U CN 202020832278 U CN202020832278 U CN 202020832278U CN 214220433 U CN214220433 U CN 214220433U
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layer
core material
woven fiber
middle core
fiber layer
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龙钟江
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    • E04F2290/041—Specially adapted covering, lining or flooring elements not otherwise provided for for insulation or surface protection, e.g. against noise, impact or fire against noise
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • 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
    • E04F2290/041—Specially adapted covering, lining or flooring elements not otherwise provided for for insulation or surface protection, e.g. against noise, impact or fire against noise
    • E04F2290/043—Specially adapted covering, lining or flooring elements not otherwise provided for for insulation or surface protection, e.g. against noise, impact or fire against noise with a bottom layer for sound insulation

Abstract

本实用新型涉及复合结构技术领域，公开了一种聚氨酯复合地板，包括发泡层和设置在发泡层上的装饰层，所述发泡层包括中间芯材，所述中间芯材的上下部分别设置有连续编织纤维层，位于中间芯材上部的连续编织纤维层为上部连续编织纤维层，位于中间芯材下部的连续编织纤维层为下部连续编织纤维层，所述中间芯材上设有若干个填充空隙，若干个填充空隙内均填充有聚氨酯硬泡；本实用新型提供的一种聚氨酯复合地板，聚氨酯复合地板具有成本低、耐候性强和适应性广的优势，且采用模具一体成型，利用产品自身反应的化学内能进行相互催化熟化，大大节约了生产能耗，同时避免使用胶水粘合，更加环保耐用，加工工序简单。

Description

一种聚氨酯复合地板
技术领域
本实用新型涉及复合结构技术领域，具体涉及一种聚氨酯复合地板。
背景技术
随着经济的不断发展，人民的生活水平得到极大提高，但同时也带来了自然资源极度的消耗，地球的森林覆盖率在不断的减少，面对实木资源日渐匮乏，全球气候变暖，海平面不断上升，等全球化带来深渊影响的同时。人类耐以生存的环境面临着前所未有的巨大威胁。
面对目前市面上不管是实木地板还是PVC、PE木塑地板，都存在着很多产品缺陷。例如：产品容易收缩变形，粉化崩边，老化开裂，霉变，等等诸多存在已久的产品问题，严重的降低了木塑地板的使用效果，进而降低了木塑地板的使用寿命，不能满足户外不同环境的长期使用需求。
实用新型内容
针对上述现有技术中存在的问题，本实用新型提供一种聚氨酯复合地板，聚氨酯复合地板具有成本低、耐候性强和适应性广的优势，且采用模具一体成型，利用产品自身反应的化学内能进行相互催化熟化，大大节约了生产能耗，同时避免使用胶水粘合，更加环保耐用，加工工序简单。
本实用新型所采用的技术方案为：
如图1所示，一种聚氨酯复合地板，包括发泡层和设置在发泡层上的装饰层，所述发泡层包括中间芯材，所述中间芯材的上下部分别设置有连续编织纤维层，位于中间芯材上部的连续编织纤维层为上部连续编织纤维层，位于中间芯材下部的连续编织纤维层为下部连续编织纤维层，所述中间芯材上设有若干个填充空隙，若干个填充空隙内均填充有聚氨酯硬泡。
由于本板材是经过发泡反应之后熟化定型而成，所以具有隔音隔热的效果，此外，连续编织纤维层为板材提供水平横向的弯曲受力支撑而中间芯材为板材提供纵向压缩支撑，使得板材整体力学性能更加优异，成本更加低廉，从而更具市场竞争力。
需要说明的是，本产品的形状可以自由设计，以满足不同的使用场景，且本产品的具体设计中连续编织纤维层的层数和铺设方向以及中间芯材采用的层数可以根据实际力学需求进行灵活的添加和设计，以满足不同的使用需求。也即是，产品的形状以及力学结构可以根据需要自由设计，以满足不同场景的应用需求，适应性广。
具体的，上部连续编织纤维层和下部连续编织纤维层的层数和铺设方向以及中间芯材采用的层数可以根据实际力学需求进行灵活的添加和设计，上部连续编织纤维层和下部连续编织纤维层均是横向平面延伸状态，中间芯材为纵向支撑体，也即是整体呈“工”字形结构，当然可以是单层“工”字形结构，也可以是多“工”字形结构，单“工”字形结构即夹心结构为中间芯材上下部分别设置上部连续编织纤维层和下部连续编织纤维层，多“工”字形结构即夹心结构为两层中间芯材之间设置多层连续编织纤维层，中间芯材的表面还设有连续编织纤维层。
发泡层的设置，拥有比原木有更好的尺寸稳定性、防腐蚀性，防虫、防潮，材料的利用率高，极低的VOCs释放，环境友好，可回收再用。
由于我们采用的原木纹理成型技术，通过处理原木模板，将原木模板纹路处理出来，再成型到模具，最后通过模具将原木纹路成型到产品每个面上，所制得的复合地板产品的外观更加自然美观，相对与传统的木塑产品，具有更好的木质感。
在保留了极富生命力的自然木质感的同时，克服了原木在实际环境应用中所暴露出吸水变形、霉变、开裂、翘曲、易燃、易受虫害真菌的侵蚀等致命弱点。
进一步的，所述聚氨酯硬泡由如下重量份数的各组分组成：聚醚多元醇40-60份、异氰酸酯40-60份、填料10-30份、偶联剂3-6份、阻燃剂8-16份和助剂3-6份。
进一步的，所述聚氨酯硬泡由如下重量份数的各组分组成：聚醚多元醇40份、异氰酸酯40、填料10份、偶联剂3份、阻燃剂8份和助剂3份。
进一步的，所述聚氨酯硬泡由如下重量份数的各组分组成：聚醚多元醇60份、异氰酸酯60份、填料30份、偶联剂6份、阻燃剂16份和助剂6份。
进一步的，所述聚氨酯硬泡由如下重量份数的各组分组成：聚醚多元醇50份、异氰酸酯50份、填料20份、偶联剂5份、阻燃剂12份和助剂5份。
所述助剂为分散剂、成膜助剂、增稠剂、消泡剂、活性剂、渗透剂、调色剂和悬浮剂中的至少一种，所述填料为砂、水泥、石英粉、重钙粉、滑石粉、粉煤灰、矿粉和硅灰中的至少一种。
进一步的，所述连续编织纤维层选自人造纤维、金属合金丝、芳纶纤维、石英纤维、玻璃纤维、玄武岩纤维和植物纸质纤维中的一种或几种。
进一步的，所述中间芯材采用高分子材料、金属材质、有机生物材质或无机材质。
具体的，高分子材料可选PP、PE、PET、PC、ABS或PVC，金属材质可以采用铜、铝、钢铁或合金材质。
需要说明的是，所述中间芯材可以采用蜂窝结构芯材或格栅结构芯材。
当然，中间芯材也可以采用其他多空芯材。
进一步的，所述装饰层包括从下至上依次设置的橡胶层、底漆层、面漆层和保护漆层。
由于复合了相应的橡胶层，因为橡胶层具有回弹性，当钉子打入本复合地板中时，橡胶层会自动修复，从而很好的覆盖隐藏钉子尾，使得装饰效果更加美观，不仅节约资源，同时还经久耐用，户外长期使用可达20年以上，且能够二次回收利用，很好的解决实木匮乏的难题。
本聚氨酯复合地板的制作工艺，包括以下工艺步骤：
A、向下模具内喷涂脱模剂，之后再依次喷涂保护漆层，滚涂面漆层，喷涂底漆层；
B、待漆膜实干后，浇注橡胶弹性体料，成型橡胶层；
C、在橡胶层上放置上部连续编织纤维层；
D、浇注聚氨酯发泡料：
按以下组份及含量进行配料：聚醚多元醇40-60份、异氰酸酯40-60份、填料10-30份、偶联剂3-6份、阻燃剂8-16份和助剂3-6份，将以上配料通过混合装置均匀混合形成聚氨酯发泡料，最后注入模具中；
E、聚氨酯发泡料浇注完成后，放置中间芯材；
F、在中间芯材上放置下部连续编织纤维层；
G、合模熟化；
H、脱模，清理模具；
I、去除多余的溢料飞边，得到聚氨酯复合地板。
由于发泡层、橡胶层、底漆层、面漆层和保护漆层采用模具一体成型，利用产品自身反应的化学内能进行相互催化熟化，大大节约了生产能耗，同时避免使用胶水粘合，更加环保耐用，加工工序简单。
合模之后注入模具内的聚氨酯发泡料反应发泡膨胀，继而在模腔中产生高温高压的成型环境，通过聚氨酯发泡料将上部连续编织纤维层和下部连续编织纤维层固定在中间芯材上，且由于中间芯材具有填充空隙，聚氨酯发泡料发泡填充在填充空隙内，解决了填充空隙处强度较低的问题，使得中间芯材与连续编织纤维层形成一个整体，增加了复合地板的整体强度。
需要说明的是，合模之后，由于聚氨酯发泡料发泡过程中释放大量热量，体积变大，因模具的限制，会产生很大的模腔压力，在高温高压成型的过程中，在接触上模处的聚氨酯发泡料由于上模成型表面的温差，表面会产生表层结皮，表层结皮的密度大，强度更高，使得产品的下部表面强度更高，下部连续编织纤维层会被表层结皮结合在一起，下部连续编织纤维层固定的更为牢靠，使得整个产品的强度更高。综上，本工艺利用产品自身反应的化学内能进行相互催化熟化，大大节约了生产能耗和生产成本。
本实用新型的有益效果为：由于本板材是经过发泡反应之后熟化定型而成，所以具有隔音隔热的效果，此外，连续编织纤维层为板材提供水平横向的弯曲受力支撑而中间芯材为板材提供纵向压缩支撑，使得板材整体力学性能更加优异，成本更加低廉，从而更具市场竞争力。
需要说明的是，本产品的形状可以自由设计，以满足不同的使用场景，且本产品的具体设计中连续编织纤维层的层数和铺设方向以及中间芯材采用的层数可以根据实际力学需求进行灵活的添加和设计，以满足不同的使用需求。也即是，产品的形状以及力学结构可以根据需要自由设计，以满足不同场景的应用需求，适应性广。
具体的，上部连续编织纤维层和下部连续编织纤维层的层数和铺设方向以及中间芯材采用的层数可以根据实际力学需求进行灵活的添加和设计，上部连续编织纤维层和下部连续编织纤维层均是横向平面延伸状态，中间芯材为纵向支撑体，也即是整体呈“工”字形结构，当然可以是单层“工”字形结构，也可以是多“工”字形结构，单“工”字形结构即夹心结构为中间芯材上下部分别设置上部连续编织纤维层和下部连续编织纤维层，多“工”字形结构即夹心结构为两层中间芯材之间设置多层连续编织纤维层，中间芯材的表面还设有连续编织纤维层。
发泡层的设置，拥有比原木有更好的尺寸稳定性、防腐蚀性，防虫、防潮，材料的利用率高，极低的VOCs释放，环境友好，可回收再用。
由于我们采用的原木纹理成型技术，通过处理原木模板，将原木模板纹路处理出来，再成型到模具，最后通过模具将原木纹路成型到产品每个面上，所制得的复合地板产品的外观更加自然美观，相对与传统的木塑产品，具有更好的木质感。
在保留了极富生命力的自然木质感的同时，克服了原木在实际环境应用中所暴露出吸水变形、霉变、开裂、翘曲、易燃、易受虫害真菌的侵蚀等致命弱点。
此外，由于发泡层、橡胶层、底漆层、面漆层和保护漆层采用模具一体成型，利用产品自身反应的化学内能进行相互催化熟化，大大节约了生产能耗，同时避免使用胶水粘合，更加环保耐用，加工工序简单。
合模之后注入模具内的聚氨酯发泡料反应发泡膨胀，继而在模腔中产生高温高压的成型环境，通过聚氨酯发泡料将上部连续编织纤维层和下部连续编织纤维层固定在中间芯材上，且由于中间芯材具有填充空隙，聚氨酯发泡料发泡填充在填充空隙内，解决了填充空隙处强度较低的问题，使得中间芯材与连续编织纤维层形成一个整体，增加了复合地板的整体强度。
需要说明的是，合模之后，由于聚氨酯发泡料发泡过程中释放大量热量，体积变大，因模具的限制，会产生很大的模腔压力，在高温高压成型的过程中，在接触上模处的聚氨酯发泡料由于上模成型表面的温差，表面会产生表层结皮，表层结皮的密度大，强度更高，使得产品的下部表面强度更高，下部连续编织纤维层会被表层结皮结合在一起，下部连续编织纤维层固定的更为牢靠，使得整个产品的强度更高。综上，本工艺利用产品自身反应的化学内能进行相互催化熟化，大大节约了生产能耗和生产成本。
附图说明
图1是本实用新型的结构示意图；
图2是本实用新型的另一种结构的结构示意图。
图中：中间芯材1；上部连续编织纤维层2；下部连续编织纤维层3；橡胶层4；底漆层5；面漆层6；保护漆层7。
具体实施方式
为使本实用新型实施例的目的、技术方案和优点更加清楚，下面将结合本实用新型实施例中的附图，对本实用新型实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例是本实用新型一部分实施例，而不是全部的实施例。通常在此处附图中描述和示出的本实用新型实施例的组件可以以各种不同的配置来布置和设计。
因此，以下对在附图中提供的本实用新型的实施例的详细描述并非旨在限制要求保护的本实用新型的范围，而是仅仅表示本实用新型的选定实施例。基于本实用新型中的实施例，本领域普通技术人员在没有作出创造性劳动前提下所获得的所有其他实施例，都属于本实用新型保护的范围。
需要说明的是，在不冲突的情况下，本实用新型中的实施例及实施例中的特征可以相互组合。
下面结合附图及具体实施例对本实用新型作进一步阐述。
实施例1：
如图1所示，本实施例提供一种聚氨酯复合地板，包括发泡层和设置在发泡层上的装饰层，发泡层包括中间芯材1，中间芯材1的上下部分别设置有连续编织纤维层，位于中间芯材1上部的连续编织纤维层为上部连续编织纤维层2，位于中间芯材1下部的连续编织纤维层为下部连续编织纤维层3，中间芯材1上设有若干个填充空隙，若干个填充空隙内均填充有聚氨酯硬泡。
由于本板材是经过发泡反应之后熟化定型而成，所以具有隔音隔热的效果，此外，连续编织纤维层为板材提供水平横向的弯曲受力支撑而中间芯材1为板材提供纵向压缩支撑，使得板材整体力学性能更加优异，成本更加低廉，从而更具市场竞争力。
需要说明的是，本产品的形状可以自由设计，以满足不同的使用场景，且本产品的具体设计中连续编织纤维层的层数和铺设方向以及中间芯材1采用的层数可以根据实际力学需求进行灵活的添加和设计，以满足不同的使用需求。也即是，产品的形状以及力学结构可以根据需要自由设计，以满足不同场景的应用需求，适应性广。
如图2所示，上部连续编织纤维层2和下部连续编织纤维层3的层数和铺设方向以及中间芯材1采用的层数可以根据实际力学需求进行灵活的添加和设计，上部连续编织纤维层2和下部连续编织纤维层3均是横向平面延伸状态，中间芯材1为纵向支撑体，也即是整体呈“工”字形结构，当然可以是单层“工”字形结构，也可以是多“工”字形结构，单“工”字形结构即夹心结构为中间芯材1上下部分别设置上部连续编织纤维层2和下部连续编织纤维层3，多“工”字形结构即夹心结构为两层中间芯材1之间设置多层连续编织纤维层，中间芯材1的表面还设有连续编织纤维层。
发泡层的设置，拥有比原木有更好的尺寸稳定性、防腐蚀性，防虫、防潮，材料的利用率高，极低的VOCs释放，环境友好，可回收再用。
由于我们采用的原木纹理成型技术，通过处理原木模板，将原木模板纹路处理出来，再成型到模具，最后通过模具将原木纹路成型到产品每个面上，所制得的复合地板产品的外观更加自然美观，相对与传统的木塑产品，具有更好的木质感。
在保留了极富生命力的自然木质感的同时，克服了原木在实际环境应用中所暴露出吸水变形、霉变、开裂、翘曲、易燃、易受虫害真菌的侵蚀等致命弱点。
实施例2：
本实施例是在上述实施例1的基础上进行优化。
聚氨酯硬泡由如下重量份数的各组分组成：聚醚多元醇50份、异氰酸酯50份、填料20份、偶联剂5份、阻燃剂12份和助剂5份。助剂为分散剂、成膜助剂、增稠剂、消泡剂、活性剂、渗透剂、调色剂和悬浮剂中的至少一种，本实施例中选择分散剂，填料为砂、水泥、石英粉、重钙粉、滑石粉、粉煤灰、矿粉和硅灰中的至少一种，本实施例中选择矿粉。
实施例3：
本实施例是在上述实施例2的基础上进行优化。
聚氨酯硬泡由如下重量份数的各组分组成：聚醚多元醇40份、异氰酸酯40、填料10份、偶联剂3份、阻燃剂8份和助剂3份。
实施例4：
本实施例是在上述实施例2的基础上进行优化。
聚氨酯硬泡由如下重量份数的各组分组成：聚醚多元醇60份、异氰酸酯60份、填料30份和、偶联剂6份、阻燃剂16份和助剂6份。
实施例5：
本实施例是在上述实施例2的基础上进行优化。
连续编织纤维层选自人造纤维、金属合金丝、芳纶纤维、石英纤维、玻璃纤维、玄武岩纤维和植物纸质纤维中的一种或几种。本实施例中，连续编织纤维层2采用玻璃纤维。
实施例6：
本实施例是在上述实施例1的基础上进行优化。
中间芯材1采用高分子材料、金属材质、有机生物材质或无机材质。本实施例中，中间芯材1采用高分子材料。
具体的，高分子材料可选PP、PE、PET、PC、ABS或PVC，金属材质可以采用铜、铝、钢铁或合金材质。本实施例中，具体的中间芯材1采用PP材质。
需要说明的是，中间芯材1可以采用蜂窝结构芯材或格栅结构芯材，本实施例中采用蜂窝结构芯材。
当然，中间芯材也可以采用其他多空芯材。
实施例7：
本实施例是在上述实施例1的基础上进行优化。
装饰层包括从下至上依次设置的橡胶层4、底漆层5、面漆层6和保护漆层7。
由于复合了相应的橡胶层4，因为橡胶层4具有回弹性，当钉子打入本复合地板中时，橡胶层4会自动修复，从而很好的覆盖隐藏钉子尾，使得装饰效果更加美观，不仅节约资源，同时还经久耐用，户外长期使用可达20年以上，且能够二次回收利用，很好的解决实木匮乏的难题。
本聚氨酯复合地板的制作工艺，包括以下工艺步骤：
A、向下模具内喷涂脱模剂，之后再依次喷涂保护漆层7，滚涂面漆层6，喷涂底漆层5；
B、待漆膜实干后，浇注橡胶弹性体料，成型橡胶层4；
C、在橡胶层4上放置上部连续编织纤维层2；
D、浇注聚氨酯发泡料：
按以下组份及含量进行配料：聚醚多元醇50份、异氰酸酯50份、填料20份、偶联剂5份、阻燃剂12份和助剂5份，将以上配料通过混合装置均匀混合形成聚氨酯发泡料，最后注入模具中；
E、聚氨酯发泡料浇注完成后，放置中间芯材1，本实施例中，中间芯材1采用蜂窝结构芯材；
F、在中间芯材1上放置下部连续编织纤维层3；
G、合模熟化；
H、脱模，清理模具；
I、去除多余的溢料飞边，得到聚氨酯复合地板。
需要说明的是，步骤D中，预制聚氨酯发泡料，其中也可以按照实施例3或实施例4中的组分配比进行配料。
此外，由于发泡层、橡胶层4、底漆层5、面漆层6和保护漆层7采用模具一体成型，利用产品自身反应的化学内能进行相互催化熟化，大大节约了生产能耗，同时避免使用胶水粘合，更加环保耐用，加工工序简单。
合模之后注入模具内的聚氨酯发泡料反应发泡膨胀，继而在模腔中产生高温高压的成型环境，通过聚氨酯发泡料将上部连续编织纤维层和下部连续编织纤维层固定在中间芯材上，且由于中间芯材具有填充空隙，聚氨酯发泡料发泡填充在填充空隙内，解决了填充空隙处强度较低的问题，使得中间芯材与连续编织纤维层形成一个整体，增加了复合地板的整体强度。
需要说明的是，合模之后，由于聚氨酯发泡料发泡过程中释放大量热量，体积变大，因模具的限制，会产生很大的模腔压力，在高温高压成型的过程中，在接触上模处的聚氨酯发泡料由于上模成型表面的温差，表面会产生表层结皮，表层结皮的密度大，强度更高，使得产品的下部表面强度更高，下部连续编织纤维层会被表层结皮结合在一起，下部连续编织纤维层固定的更为牢靠，使得整个产品的强度更高。综上，本工艺利用产品自身反应的化学内能进行相互催化熟化，大大节约了生产能耗和生产成本。
本实用新型不局限于上述可选实施方式，任何人在本实用新型的启示下都可得出其他各种形式的产品，但不论在其形状或结构上作任何变化，凡是落入本实用新型权利要求界定范围内的技术方案，均落在本实用新型的保护范围之内。

Claims (2)

1.一种聚氨酯复合地板，其特征在于：包括发泡层和设置在发泡层上的装饰层，所述发泡层包括中间芯材，所述中间芯材的上下部分别设置有连续编织纤维层，位于中间芯材上部的连续编织纤维层为上部连续编织纤维层，位于中间芯材下部的连续编织纤维层为下部连续编织纤维层，所述中间芯材上设有若干个填充空隙，若干个填充空隙内均填充有聚氨酯硬泡。
2.根据权利要求1所述的一种聚氨酯复合地板，其特征在于：所述装饰层包括从下至上依次设置的橡胶层、底漆层、面漆层和保护漆层。
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