RU2794159C1 - Co-extruded stone plastic composite foam flooring and method of its manufacturing - Google Patents

Abstract

FIELD: foam flooring.

SUBSTANCE: invention relates to a stone plastic composite (SPC) foam flooring, and to a method for producing the same. The SPC foam floor covering, containing the structure of the stone plastic base material, sequentially contains from top to bottom: the first stable layer, the foam layer and the second stable layer; where the first stable layer and the second stable layer are sheets with PVC resin and powder filler as the main components, 25-40 weight fractions of PVC resins and 55-75 weight fractions filler powder; wherein said foam layer is located between said first and said second stable layers to reduce the overall density of the flooring of the rock-plastic composite foam to 1.4-1.6 g/cm³.

EFFECT: invention provides a floor covering approximately 20-30% lighter than conventional SPC flooring and also exhibits improved dimensional stability.

10 cl, 3 dwg, 1 tbl

Description

FIELD OF TECHNOLOGY TO WHICH THE INVENTION RELATES

[0001] The present invention relates to a foam flooring, in particular to an SPC (rock plastic composite) foam flooring, as well as to a method for producing the same.

BACKGROUND OF THE INVENTION

[0002] With the continuous development of the PVC flooring industry, plastic flooring has gradually become an alternative material to traditional flooring materials such as wood floors, ceramic tiles, and reinforced flooring. Industry experts predict that in the next few years, plastic flooring will be adopted by the Chinese as a widely used decorative material for home decoration. With the rapid development of the real estate industry, the load capacity of flooring materials has become a new requirement for the decoration of high-rise buildings and commercial premises, and more stringent requirements have been placed on PVC flooring.

BRIEF DESCRIPTION OF THE INVENTION

TECHNICAL PROBLEM

[0003] Conventional SPC flooring has a density in the range of 1900-2000 kg/m ³ . The high density of SPC flooring results in increased weight per unit area during finishing and increased transport costs.

SOLUTION

TECHNICAL SOLUTION OF THE PROBLEM

[0004] The present invention provides an SPC foam floor to solve the above problem. This type of flooring is approximately 20-30% lighter than traditional SPC flooring. It also exhibits improved dimensional stability.

[0005] The technical solution of the present invention used to solve the above problem is as follows:

[0006] An SPC foam co-extruded flooring comprising a rock plastic base material structure comprising, in sequence, from top to bottom: a first stable layer, a foam layer, and a second stable layer; wherein the first stable layer and the second stable layer are sheets with PVC resin and powder filler as main components; in which the amount of PVC resin is 100 parts by weight and the amount of filler powder is 200-300 parts by weight; and the density of the SPC foam flooring is in the range of 1.4-1.6 g/cm ³ .

[0007] In a preferred embodiment of the above technical solution, the first stable layer has a thickness in the range from 1 to 5 mm; the foam layer has a thickness in the range of 2 to 10 mm; the second stable layer has a thickness in the range of 1 to 5 mm.

[0008] As a preferred embodiment of the above technical solution, the filler powder is calcium carbonate or contains calcium carbonate as the main component and one material selected from the group consisting of calcium bicarbonate, glass fiber and carbon fiber, or any mixture thereof.

[0009] As a preferred embodiment of the above technical solution, the first stable layer and the second stable layer further comprise an additive selected from the group consisting of calcium-zinc stabilizer, internal lubricant, polyethylene wax, chlorinated polyethylene, acrylate, composite lubricant and colorant, or any combination of them.

[0010] As another preferred embodiment of the above technical solution, when the foam layer is a chemical foam layer, the first stable layer and the second stable layer further contain the following components in parts by weight: 100 parts of PVC resin powder, 200-300 parts calcium carbonate, 4-7 parts of calcium-zinc stabilizer, 0.8-1.3 parts of internal lubricant, 0.8-1.5 parts of polyethylene wax, 4-6 parts of chlorinated polyethylene, 2-5 parts of acrylate, 1.0 -1.5 parts of composite lubricant and 0.4-0.6 parts of dye.

[0011] As another preferred embodiment of the above technical solution, when the foamed layer is a physical foaming layer, the first stable layer and the second stable layer further contain the following components by weight: 100 parts of PVC resin powder, 250-270 parts of carbonate calcium, 5-6 parts of calcium-zinc stabilizer, 1.0-1.2 parts of internal lubricant, 1.3-1.5 parts of polyethylene wax, 5-6 parts of chlorinated polyethylene, 2-3 parts of acrylate, 1.1- 1.3 parts of composite lubricant and 0.4-0.5 parts of dye.

[0012] Lubricants are divided into two types: internal lubrication and external lubrication. The main function of external lubrication is to improve the friction between the polymer melt material and the hot metal surface of the machine. It is poorly compatible with the polymer and easily migrates out of the meltable material, and thus can form a thin lubricant layer at the interface between the plastic meltable material and metal. Internal lubricants are highly compatible with polymers and are present within polymers to reduce the cohesive force within polymer molecules in order to improve frictional heat generation and fluidity of the plastic meltable material. The external lubricants readily migrate outward from the meltable material, facilitating the release of the plastic meltable material from the mold after molding, so that the external lubricants are commonly referred to as mold release. However, internal lubricants and external lubricants may vary depending on the properties of the consumable material. For example, polyethylene wax and stearic acid are common lubricants; when used in polyethylene resin, polyethylene wax is highly compatible with polyethylene resin and remains inside the resin as an internal lubricant; when used in PVC resin, stearic acid is highly compatible and retains within the resin as an internal lubricant, while polyethylene wax is poorly compatible and migrates outside the resin as an external lubricant.

[0013] Composite lubricants generally refer to esters of polyhydric alcohols. Such lubricants include those containing polyhydric alcohol esters obtained by esterification, alcoholysis and interesterification of fatty acids such as caprylic acid, decanoic acid, lauric acid, palmitic acid, oleic acid, stearic acid, arachidic acid, adipic acid and sebacic acid. acid, or polymeric composite products of alcohol esters formed by repeated esterification and compounding of such fatty acids. In such lubricants, the polyhydric alcohol in polyhydric alcohol ester products is partially esterified, so unreacted hydroxyl groups are present in the ester. Polar hydroxyl groups generally give products an excellent antistatic effect. Therefore, these lubricants also serve as an antistatic agent in the processing of PVC. Pentaerythritol fatty acid ester is a mixture containing monoester, diester, triester and tetraester, and exhibits excellent internal lubrication effect in PVC processing. Due to the difference in the degree of reaction, this type of product changes from internal lubrication to external lubrication as the amount of hydroxyl groups increases.

[0014] As a preferred embodiment of the above technical solution, the foam layer is a chemical foam layer containing the following components in parts by weight: 100 parts of PVC resin powder, 150-200 parts of calcium carbonate, 4-7 parts of calcium-zinc stabilizer, 0.6-1.2 parts foaming agent, 0.5-0.9 parts polyethylene wax, 2-3 parts chlorinated PVC, 2-3 parts acrylate, 0.3-0.8 parts lubricant and 6-9 parts foam regulator .

[0015] As another preferred embodiment of the above technical solution, the blowing agent contains from 0.4 to 0.6 parts of the dye.

[0016] As another preferred embodiment of the above technical solution, the foam layer is a physical foam layer containing the following components in parts by weight: 100 parts of PVC resin powder, 300-330 parts of calcium carbonate, 4-7 parts of calcium-zinc stabilizer, 1-1.5 parts of internal lubricant, 1-1.5 parts of polyethylene wax, 4-8 parts of chlorinated polyethylene, 3-5 parts of acrylate and 0.7-1.2 parts of composite lubricant.

[0017] As another preferred embodiment of the above technical solution, the blowing agent contains from 0.4 to 0.6 parts of the dye.

[0018] As another preferred embodiment of the aforementioned technical solution, the SPC foam flooring further comprises a decorative and protective structure, sequentially containing, from top to bottom, a UV coating, a wear layer and a decorative layer.

[0019] As a preferred embodiment of the above technical solution, the UV coating has a thickness in the range of 30 to 150 microns; and the wear layer is a polymer layer with a thickness of 0.1 to 1.0 mm.

[0020] As a preferred embodiment of the above technical solution, the wear layer contains PVC resin or vinyl resin as a main component and is formed by blow molding, extrusion or drawing processes after adding a suitable amount of plasticizer, lubricant and stabilizer.

[0021] As a preferred embodiment of the above technical solution, the decorative layer is a PVC film with a pattern on the surface.

[0022] It is another object of the present invention to provide a method for manufacturing an SPC foam flooring.

[0024] The method comprises the following steps:

[0024] a. Feeding the raw material for the first stable layer and the second stable layer into a high-speed mixer, mixing and heating the raw material, cooling the mixture with low-speed mixing, extruding the mixture from extruder A;

[0025]b. Feeding the raw material for the foam into the high-speed mixer, mixing and heating the raw material, cooling the raw material with low-speed mixing, introducing the raw material into the extruder B; in the case of chemical foaming, performing uniform plasticization of the melt and extrusion of raw materials from extruder B; in the case of physical foaming, performing uniform plasticization of the melt in extruder B, injecting 4-10 wt.% liquefied carbon dioxide at high pressure into the blowing agent injection device, maintaining high pressure in the mold cavity to keep the carbon dioxide in a liquid state so that it is completely mixed with material, and pressure relief during extrusion;

[0026] c. co-extruding the mixture through the hole of the extrusion die to form a stone-plastic structure of the base material by allowing the extrudate of extruder A to enter the distributor of the mold channel and to bring it into contact with the extrudate of extruder B in the extrusion die;

[0027] d: Passing the released plate through the area between the background pattern roller and the first mirror finish roller to form the background pattern by compression, transferring the structure of the stone plastic base material to the area between the second mirror finish roller and the roller for embossing; moving the wear-resistant layer supply roller and the decorative layer supply roller of the wear-resistant layer and the decorative paper, respectively, to a region between the second mirror finishing roller and the air-bleeding roller, performing pre-laminating; laminating the wear layer and the decorative paper on the base material layer by the action of the second mirror finish roller and the embossing roller to form the wear layer and the decorative layer, as well as a surface pattern with a concave and convex three-dimensional effect on the front side.

BENEFICIAL EFFECTS OF THE INVENTION

Benefits:

[0028] Thus, the present invention provides the following beneficial effects:

[0029] In the present invention, the foam layer is located between two stable layers to significantly reduce the overall density of the floor covering to 1.4-1.6 g/m ³ . Since the foam layer is located inside, it does not affect the surface strength of the flooring, and the sound-absorbing performance of the flooring is improved, and tests prove that the dimensional stability of the present invention is greatly improved.

BRIEF DESCRIPTION OF THE DRAWINGS

DESCRIPTION OF THE DRAWINGS

[0030] FIG. 1 shows a schematic diagram depicting the structure of the present invention;

[0031] FIG. 2 is a schematic diagram showing the apparatus of the present invention;

[0032] FIG. 3 is a schematic diagram showing the apparatus according to Example 1 of the present invention;

[0033] where 1 is UV coating, 2 is wear layer, 3 is decorative layer, 4 is first stable layer, 5 is foam layer, 6 is second stable layer, 10 is background pattern roll, 20 is first mirror finish roll ; 30 second roller for mirror finish, 40 embossing roller, 200 guide roller for wear layer, 300 guide roller for decoration layer, 400 air outlet roller.

THE MOST PREFERRED EMBODIMENT FOR CARRYING OUT THE INVENTION

BEST MODE FOR CARRYING OUT THE INVENTION

[0034] As shown in FIG. 1, SPC foam co-extruded flooring contains a decorative and protective structure and a stone plastic structure of the base material.

[0035] The decorative-protective structure sequentially comprises, from top to bottom, a UV coating (1), a wear-resistant layer (2) and a decorative layer (3); the stone-plastic structure of the base material sequentially contains, from top to bottom, the first stable layer (4), the foamed layer (5) and the second stable layer (6). The density of the SPC foam flooring is 1.531 g/cm ³ .

[0036] In this Example, the thickness of the UV coating (1) is 100 µm.

[0037] The wear layer (2) contains PVC resin as the main component and is obtained by a calendering process after adding appropriate amounts of plasticizer, lubricant and stabilizer. Its thickness is 0.3 mm.

[0038] The decorative layer (3) is a PVC film with a surface pattern. Its thickness is 0.07 mm.

[0039] The first stable layer (4) and the second stable layer (6) are both sheets with PVC resin and powder filler as main components; wherein the amount of PVC resin is 100 parts by mass, the filler powder is calcium carbonate in the amount of 250 parts by mass, and in addition, additives are added containing the following components by mass:

[0040] 5 parts calcium zinc stabilizer

[0041] 1.0 parts internal lubricant

[0042] 1.4 parts polyethylene wax

[0043] 5 parts chlorinated polyethylene

[0044] 2 parts acrylate

[0045] 1.1 parts composite lubricant

[0046] 0.5 parts dye

[0047] The above auxiliary agents are conventional auxiliary agents in the art, so there is no need to go into details.

[0048] The foam layer (5) is a chemical foam layer containing the following components in parts by weight:

[0049] 100 parts PVC resin powder

[0050] 160 parts calcium carbonate

[0051] 6 parts calcium zinc stabilizer

[0052] 0.8 parts foaming agent

[0053] 0.6 parts polyethylene wax

[0054] 2 parts chlorinated PVC

[0055] 2 parts acrylate

[0056] 0.5 part lubricant

[0057] 7 parts foam regulator

[0058] 0.5 parts dye

[0059] The above auxiliary agents are conventional auxiliary agents in the art, so there is no need to go into details.

[0060] As shown in FIG. 2, the preparation method of the SPC foam flooring of this Example is as follows:

[0061] a) Raw materials for the first stable layer (4) and the second stable layer (6) are fed into the high speed mixer, mixed and heated, cooled in the low speed mixer, and extruded from extruder A;

[0062] b) The raw material for the foam layer (5) is fed into a high-speed mixer, mixed and heated, cooled with slow stirring, introduced into the extruder B, subjected to melt plasticization, and extruded from the extruder B;

[0063] c) The extrudate of extruder A enters the mold channel distributor and converges with the extrudate of extruder B in the die, and the mixture is co-extruded through the orifice of the die to form a rock plastic base material structure;

[0064] d) The plate, released from the mold, passes through the area between the background pattern roller (10) and the first mirror finish roller (20) to form the background pattern by compression, the stone-plastic structure of the base material is transferred to the area between the second roller (30) for mirror finishing and roller (40) for embossing; the wear layer and the decorative paper are transferred by the wear layer supply roller (200) and the decorative layer supply roller (300) to the area between the second mirror finish roller (30) and the air exhaust roller (400) and are pre-laminated; the wear layer and the decorative paper are laminated on the base material layer by the action of the second mirror finish roller (30) and the embossing roller (40) to form a wear layer and a decorative layer, as well as a surface pattern with a concave and convex three-dimensional effect on the front side.

[0065] A comparison of properties between the most preferred embodiment and conventional stone plastic flooring (no foaming) is shown in the Table below.

[0066]

Tested indicator test standard Test results ABA coextruded stone plastic flooring ABA Foamed Rock Plastic Flooring (Preferred) Coefficient of dimensional change after heating ISO 23999 0.13% 0.08% Twisting after heating ISO 23999 Density ISO 23996 1.984 g/ ^cm3 1.531 g/ ^cm3

Examples of the present invention

EMBODIMENTS OF THE PRESENT INVENTION

[0067] As shown in FIG. 1, SPC foam co-extruded flooring contains a decorative and protective structure and a stone plastic structure of the base material.

[0068] The decorative-protective structure sequentially comprises, from top to bottom, a UV coating (1), a wear-resistant layer (2) and a decorative layer (3); the stone-plastic structure of the base material sequentially contains, from top to bottom, the first stable layer (4), the foamed layer (5) and the second stable layer (6). The density of the SPC foam flooring is 1.465 g/cm ³ .

[0069] In this Example, the thickness of the UV coating (1) is 100 µm.

[0070] The wear layer (2) contains PVC resin as the main component and is obtained by a calendering process after adding appropriate amounts of plasticizer, lubricant and stabilizer. Its thickness is 0.3 mm.

[0071] The decorative layer (3) is a PVC film with a surface pattern. Its thickness is 0.07 mm.

[0072] The first stable layer (4) and the second stable layer (6) are both sheets with PVC resin and powder filler as main components; wherein the amount of PVC resin is 100 parts by mass, the filler powder is calcium carbonate in the amount of 250 parts by mass, and in addition, additives are added containing the following components by mass:

[0073] 5 parts calcium zinc stabilizer

[0074] 1.0 parts internal lubricant

[0075] 1.4 parts polyethylene wax

[0076] 5 parts chlorinated polyethylene

[0077] 2 parts acrylate

[0078] 1.1 parts composite lubricant

[0079] 0.5 parts dye

[0080] The above auxiliary agents are conventional auxiliary agents in the art, so there is no need to go into details.

[0081] The foam layer (5) is a physical foam layer containing the following components in parts by weight:

[0082] 100 parts of PVC resin powder

[0083] 330 parts calcium carbonate

[0084] 5.5 parts calcium zinc stabilizer

[0085] 1.2 parts internal lubricant

[0086] 1 part polyethylene wax

[0087] 5.5 parts of chlorinated polyethylene

[0088] 3 parts acrylate

[0089] 1.0 parts composite lubricant

[0090] The above auxiliary agents are conventional auxiliary agents in the art, so there is no need to go into details.

[0091] As shown in FIG. 3, the preparation method of the SPC foam flooring of this Example is as follows:

[0092] a) Raw materials for the first stable layer (4) and the second stable layer (6) are fed into a high speed mixer, mixed and heated, cooled with slow mixing, and extruded from extruder A;

[0093] b) The raw material for the foam layer (5) is fed into the high-speed mixer, introduced into the extruder B, mixed and heated, cooled with slow stirring, subjected to uniform melt plasticization in the extruder B; 6 wt% high pressure liquefied carbon dioxide is injected into the blowing agent injection device, high pressure is maintained in the mold cavity to keep the carbon dioxide in liquid state so that it is completely mixed with the material, and the pressure is released during the extrusion process;

[0094] c) The extrudate of extruder A enters the mold channel distributor and converges with the extrudate of extruder B in the die, and the mixture is co-extruded through the orifice of the die to form a rock plastic base material structure;

[0095] d) The plate, released from the mold, passes through the area between the background pattern roller (10) and the first mirror finish roller (20) to form the background pattern by compression, the stone plastic structure of the base material is transferred to the area between the second roller (30) for mirror finishing and roller (40) for embossing; the wear layer and the decorative paper are transferred by the wear layer supply roller (200) and the decorative layer supply roller (300) to the area between the second mirror finish roller (30) and the air exhaust roller (400) and are pre-laminated; the wear layer and the decorative paper are laminated on the base material layer by the action of the second mirror finish roller (30) and the embossing roller (40) to form a wear layer and a decorative layer, as well as a surface pattern with a concave and convex three-dimensional effect on the front side.

Claims (14)

1. A co-extruded stone plastic composite foam flooring comprising a stone plastic base material structure comprising, in sequence, from top to bottom: a first stable layer (4), a foam layer (5), and a second stable layer (6); wherein the first stable layer (4) and the second stable layer (6) are sheets with PVC resin and powder filler as main components; moreover, the amount of PVC resin is 100 parts by mass, and the amount of filler powder is 200-300 parts by mass; and wherein said foam layer is positioned between said first and said second stable layers to reduce the overall density of the rock plastic composite foam flooring to 1.4-1.6 g/cm ³ . 2. Flooring according to claim 1, in which the thickness of the first stable layer (4) is in the range of 1-5 mm; the thickness of the foam layer (5) is in the range of 2-10 mm; and the thickness of the second stable layer (6) is in the range of 1-5 mm. 3. The flooring according to claim 1, wherein the filler powder is calcium carbonate or contains calcium carbonate as the main component and one material selected from the group consisting of calcium bicarbonate, glass fiber and carbon fiber, or any mixture thereof. 4. Floor covering according to claim 1, in which the first stable layer (4) and the second stable layer (6) additionally contain an additive selected from the group consisting of calcium-zinc stabilizer, internal lubricant, polyethylene wax, chlorinated polyethylene, acrylate, composite lubricant and dye, or any combination thereof. 5. Floor covering according to claim 1, in which the foam layer (5) is a chemical foam layer containing the following components in parts by weight: 100 parts of PVC resin powder, 150-200 parts of calcium carbonate, 4-7 parts of calcium zinc stabilizer, 0.6-1.2 parts foaming agent, 0.5-0.9 parts polyethylene wax, 2-3 parts chlorinated polyvinyl chloride, 2-3 parts acrylate, 0.3-0.8 parts lubricant and 6-9 parts of the foam regulator. 6. Floor covering according to claim 5, in which the foam layer (5) contains 0.3-0.5 wt.h. dye. 7. The flooring according to claim 1, wherein the foamed layer (5) is a physical foaming layer containing the following components in parts by weight: 100 parts of PVC resin powder, 300-330 parts of calcium carbonate, 4-7 parts of calcium carbonate zinc stabilizer, 1-1.5 parts of internal lubricant, 1-1.5 parts of polyethylene wax, 4-8 parts of chlorinated polyethylene, 3-5 parts of acrylate and 0.7-1.2 parts of composite lubricant. 8. Floor covering according to claim 7, in which the foam layer (5) contains 0.4-0.6 wt.h. dye. 9. Floor covering according to claim 1, which additionally contains a decorative and protective structure, sequentially containing, from top to bottom, a UV coating (1), a wear-resistant layer (2) and a decorative layer (3). 10. A method for preparing a co-extruded stone plastic composite foam flooring according to claim 9, comprising the following steps: a) feeding the raw material for the first stable layer (4) and the second stable layer (6) into a high speed mixer, mixing and heating the raw material, cooling the mixture in a low speed mixer, extruding the mixture from extruder A; b) feeding the raw material for the foam layer (5) into the high speed mixer, mixing and heating the raw material, cooling the raw material in the low speed mixer, introducing the raw material into the extruder B; in the case of chemical foaming, performing uniform plasticization of the melt and extrusion of raw materials from extruder B; in the case of physical foaming, performing uniform plasticization of the melt in extruder B, injecting 4-10 wt.% liquefied carbon dioxide under high pressure into the blowing agent injection device, maintaining high pressure in the mold cavity to keep carbon dioxide in a liquid state for its complete mixing with the material, and pressure relief during extrusion; c) co-extruding the mixture through the orifice of the extrusion die to form a rock plastic structure of the base material by allowing the extrudate of extruder A to enter the distributor of the mold channel and bring it into contact with the extrudate of extruder B in the extrusion die; d) passing the plate, released from the mold, through the area between the background pattern roller (10) and the first mirror finish roller (20) to form the background pattern by compressing, transferring the structure of the stone-plastic base material to the area between the second roller (30 ) for mirror finish and roller (40) for embossing; moving the wear layer supply roller (200) and the wear layer decorative layer supply roller (300) and the decorative paper, respectively, to the area between the second mirror finish roller (30) and the air exhaust roller (400), performing pre-laminating; laminating a wear layer and a decorative paper on the base material layer by the action of a second mirror finish roller (30) and an embossing roller (40) to form a wear layer and a decorative layer, as well as a surface pattern with a concave and convex three-dimensional effect on the front side.

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