TW202332588A - Stone plastic composite floor and preparation method thereof - Google Patents

Abstract

The present invention relates to a stone plastic composite floor and a preparation method thereof, which comprises a substrate layer, a first printing layer disposed above the substrate layer, and a anti-slip layer disposed below the substrate layer; in addition, the first printing layer may further include a Wear-resistant layer. The substrate layer mainly contains plastic alloy and stone powder, the anti-slip layer is composed of thermoplastic polyester elastomer, the first printing layer contains polyethylene and/or ethylene-vinyl acetate copolymer, and the wear-resistant layer is composed of polyethylene terephthalate. The preparation method of stone plastic composite floor includes mixing polyethylene, polyethylene terephthalate, stone powder and auxiliary agent and then granulating, extruding to make the substrate layer, and then co-extruding together with the anti-slip layer; the first printing layer is formed on the substrate layer to make a stone plastic composite floor; in addition, a wear-resistant layer can be further formed on the first printing layer.

Description

Stone plastic floor and preparation method thereof

The present invention relates to a stone plastic floor and a preparation method thereof, in particular to a stone plastic floor using waste fabrics as a material source and a preparation method thereof.

In recent years, various fast fashion and online shopping have become popular, especially due to the impact of the COVID-19 epidemic, which has accelerated the dramatic changes in consumer behavior, resulting in the global production of textile products such as clothes, pants, shoes, hats, and various backpacks and handbags. The volume is increasing year by year, and the average purchase amount per person has increased significantly.

Since online shopping does not require the establishment of a physical store, goods can be purchased at a lower price, resulting in faster replacement of old shoes, hats and clothing. This new form of consumption has swept the world, causing more waste. and cause harm to the earth's ecology.

As environmental protection issues receive increasing attention, reducing the use, recycling and recycling of various textile products has become an important issue around the world.

In addition, flooring is a necessary decoration material in buildings. The flooring materials selected vary according to different types of buildings and places, such as polyvinyl chloride (PVC) flooring, wooden flooring, polyethylene terephthalate (PET) flooring, etc. ) floor, etc. Although there are many floors made of different materials on the market, most of them are made of materials containing halogen components such as PVC due to cost considerations. However, floors made of such materials cannot be recycled and require a large amount of waste. Cost-effective disposal and burial, after burning, toxic gases will be produced to pollute the environment and cause poisoning to the human body. Therefore, the use of non-toxic, environmentally friendly, low-cost recyclable materials has become an issue that must be overcome.

In view of the above problems, the creator of the present invention thought about and designed a stone plastic floor and its preparation method, using various types of discarded textile products as materials for the stone plastic floor, in order to reduce the waste caused by various textile products and the impact on the environment. pollution, and use materials that do not contain toxic ingredients and can be recycled to reduce costs and are environmentally friendly to make stone plastic floors to reduce the amount of petrochemical materials, damage to the environment and waste of natural resources.

A first aspect of the present invention is to provide a stone plastic floor. The stone plastic floor includes a base material layer, a first printing layer disposed above the base material layer, and a first printing layer disposed below the base material layer. Sliding layer; in addition, a wear-resistant layer can be further provided above the first printing layer.

The base material layer mainly includes plastic alloy and stone powder, as well as a variety of auxiliary agents such as compatibilizers, toughening agents, slip agents, water absorbing agents, and antioxidants; preferably, the thickness of the base material layer is 4 to 8 mm. Among them, the plastic alloy includes polyethylene (PE) and polyethylene terephthalate (PET), which are mainly derived from discarded clothes, pants, shoes, hats, various backpacks, handbags, etc. Cloth; preferably, based on the weight of the base material layer, the plastic alloy and the various auxiliary agents account for a total of 35 to 55%. In addition, in the plastic alloy, the content ratio of the polyethylene and the polyethylene terephthalate is 6:4 to 8:2.

Optionally, the stone powder is selected from calcium carbonate, clay, montmorillonite, silica or talc. The smaller the particle size of the stone powder, the better its coating with each component in the base material layer; preferably Preferably, the particle size of the stone powder is 300~1500 mesh. Preferably, the stone powder accounts for 45 to 65% based on the weight of the base material layer.

Optionally, the compatibilizer is selected from styrene-ethylene-butylene-styrene copolymer (SEBS), styrene-butylene-styrene copolymer (SBS), ethylene propylene diene rubber (EPDM), Polyethylene grafted maleic anhydride (PE-g-MAH), polyethylene grafted glycidyl methacrylate (PE-g-GMA), polyolefin elastomer grafted maleic anhydride (POE-g-MAH) or A group composed of polyolefin elastomer grafted with glycidyl methacrylate (POE-g-GMA). The compatibilizer utilizes its characteristics of being compatible with both polyethylene and polyethylene terephthalate to form a blend (i.e. plastic) of polyethylene, polyethylene terephthalate and the compatibilizer. alloy); preferably, the compatibilizer accounts for 2 to 6% based on the weight of the base material layer.

Optionally, the toughening agent is selected from thermoplastic polyester elastomer (TPEE) or polyolefin elastomer (POE); preferably, the toughening agent accounts for 8 to 12% based on the weight of the base material layer. %.

Optionally, the lubricant is selected from Montan wax; preferably, the lubricant accounts for 0.3~0.7% based on the weight of the base material layer.

Optionally, the water absorbing agent is selected from calcium oxide powder; preferably, the water absorbing agent accounts for 3 to 7% based on the weight of the substrate layer.

Optionally, the antioxidant is selected from pentaerythritol tetrakis (3,5-di-tert-butyl-4-hydroxy)phenylpropanoate (Irganox ^® 1010); preferably, based on the weight of the substrate layer, The above antioxidants account for 0.3~0.7%.

The anti-slip layer is composed of thermoplastic polyester elastomer (TPEE). Preferably, the thickness of the anti-slip layer is 1~5 mm. In addition, the thermoplastic polyester elastomer used in the anti-slip layer can be further added with a foaming agent to make the thermoplastic polyester elastomer (TPEE) micro-foam (slightly expand in volume), thereby reducing its specific gravity and thus having buffering and sound insulation effects. ; Preferably, the thermoplastic polyester elastomer used in the anti-slip layer is added with a foaming agent to reduce the specific gravity to 0.4~0.6.

The first printing layer is composed of a coating layer and a pigment layer. The coating layer faces the base material layer, and the pigment layer is located above the coating layer.

The coating layer includes low-density polyethylene (LDPE), polyolefin elastomer (POE), ethylene-vinyl acetate copolymer (EVA) or any combination thereof; preferably, the coating layer uses low-density polyethylene The melting point of polyethylene, polyolefin elastomer, ethylene-vinyl acetate copolymer or any combination thereof is 90~140°C; preferably, the thickness of the coating layer is 30~80µm.

The pigment layer is composed of low melting point polyethylene terephthalate; preferably, the melting point of the low melting point polyethylene terephthalate is 130~170°C; preferably, the pigment layer The thickness is 30~50µm.

Furthermore, in order to block the background color of the base material layer, a white second printing layer can be further bonded between the base material layer and the first printing layer; the composition of the second printing layer The ingredients, melting point range and thickness are the same as those of the first printing layer, and will not be described again here.

The wear-resistant layer is composed of polyethylene terephthalate. Polyethylene terephthalate has a high crystallization rate, good optical transparency and wear resistance. Its wear resistance is that of ordinary polyvinyl chloride (PVC). ) is 2 times that of the wear-resistant layer, so polyethylene terephthalate is selected as the wear-resistant layer. Preferably, the melting point of polyethylene terephthalate in the wear-resistant layer is 170~180°C; preferably, the thickness of the wear-resistant layer is 200~500µm.

A second aspect of the present invention is to provide a method for preparing stone plastic flooring, which includes the following steps:

Step S1: Place polyethylene, polyethylene terephthalate, stone powder and various auxiliary agents in a high-speed mixer to evenly mix and evaporate the water to form a first mixture;

Step S2: Place the first mixture in a twin-screw extruder for granulation to form base material layer pellets;

Step S3: Place the base material layer pellets and the thermoplastic polyester elastomer material as the anti-slip layer in a co-extrusion extruder for co-extrusion to obtain an integrally formed base material layer and anti-slip layer;

Step S4: Place the first printing layer on top of the base material layer, use a hot press laminating machine to laminate the first printing layer on top of the base material layer, and use a double roller flattening machine to flatten the first printing layer on top of the base material layer. On the base material layer, uncut stone plastic sheets are obtained;

Step S5: After cutting the uncut stone-plastic board into the required size, use a ditch washing machine to trim the periphery of the cut stone-plastic board, and then obtain the stone-plastic floor.

In step S1, the main sources of the polyethylene and the polyethylene terephthalate are clothes, pants, shoes, hats and various types of backpacks, handbags and other waste fabrics; preferably, the base is used Based on the weight of the material layer, the plastic alloy and the various auxiliary agents account for a total of 35 to 55%. In addition, in the plastic alloy, the content ratio of the polyethylene and the polyethylene terephthalate is 6:4 to 8:2. The auxiliary agent system includes compatibilizer, toughening agent, lubricant, water absorbing agent and antioxidant.

Optionally, the stone powder is selected from calcium carbonate, clay, montmorillonite, silica or talc; preferably, the particle size of the stone powder is 300 to 1500 mesh. Preferably, the stone powder accounts for 45 to 65% based on the weight of the base material layer.

Optionally, the compatibilizer is selected from the group consisting of styrene-ethylene-butylene-styrene copolymer, styrene-butylene-styrene copolymer, ethylene propylene diene monomer rubber, polyethylene grafted maleic anhydride, polyethylene A group consisting of ethylene grafted with glycidyl methacrylate, polyolefin elastomer grafted with maleic anhydride or polyolefin elastomer grafted with glycidyl methacrylate; preferably, based on the weight of the base material layer, The compatibilizer accounts for 2~6%.

Optionally, the toughening agent is selected from thermoplastic polyester elastomer or polyolefin elastomer; preferably, the toughening agent accounts for 8 to 12% based on the weight of the base material layer.

Optionally, the lubricant is selected from Montan wax; preferably, the lubricant accounts for 0.3~0.7% based on the weight of the base material layer.

Optionally, the water absorbing agent is selected from calcium oxide powder; preferably, the water absorbing agent accounts for 3 to 7% based on the weight of the substrate layer.

Optionally, the antioxidant is selected from pentaerythritol tetrakis (3,5-di-tert-butyl-4-hydroxy)phenylpropanoate (Irganox ^® 1010); preferably, based on the weight of the substrate layer, The above antioxidants account for 0.3~0.7%.

In step S2, the screw length-to-diameter ratio of the twin-screw extruder is 48 to 56. When the screw length-to-diameter ratio is larger, the temperature segmentation can be increased to improve the mixability of each component in the first mixture. And gradually cool down slowly. Since the one with the highest melting point in the first mixture is polyethylene terephthalate (250°C), the initial feeding temperature is set slightly higher than 250°C and gradually lowered to 270°C, so that all components are completely melted. Mix to improve the mixability of each ingredient.

In step S3, the co-extrusion extruder can be adjusted by the die screw at the outlet to set the thickness of the base material layer and the anti-slip layer, and maintain the base material layer at 150°C after co-extrusion. To facilitate subsequent lamination of the printing layer. Preferably, the thickness of the base material layer is 4~8mm, and the thickness of the anti-slip layer is 1~5mm. In addition, in order to make the anti-slip layer have buffering and sound insulation effects, the thermoplastic polyester elastomer that can be used in the anti-slip layer can further add a foaming agent to make the thermoplastic polyester elastomer micro-foam (slightly expand in volume). ) to reduce its specific gravity; preferably, the thermoplastic polyester elastomer used in the anti-slip layer is added with a foaming agent to reduce its specific gravity to 0.4~0.6.

In step S4, the first printing layer is composed of a coating layer and a pigment layer. The coating layer faces the base material layer, and the pigment layer is located above the coating layer.

The coating layer includes low-density polyethylene, polyolefin elastomer, ethylene-vinyl acetate copolymer or any combination thereof; preferably, the coating layer is selected from low-density polyethylene, polyolefin elastomer, ethylene -The melting point of vinyl acetate copolymer or any combination of polymers is 90~140°C. Its melting point is lower than the temperature of 150°C maintained by the base material layer after co-extrusion in step S3, which can melt the coating layer and then fit it. on the base material layer; preferably, the thickness of the coating layer is 30~80µm.

The pigment layer is composed of low melting point polyethylene terephthalate; preferably, the melting point of the low melting point polyethylene terephthalate is 130~170°C; preferably, the pigment layer The thickness is 30~50µm.

Furthermore, in order to block the background color of the base material layer, in step S4, a white second printing layer can be further bonded between the base material layer and the first printing layer; The composition, melting point range and thickness of the second printing layer are the same as those of the first printing layer, and will not be described again here.

In addition, in order to make the surface of the stone plastic floor have better wear resistance, in step S4, a wear-resistant layer can be further attached above the first printing layer. The wear-resistant layer is made of polyethylene terephthalate. Its wear resistance is twice that of ordinary PVC wear-resistant layers, and it has good optical transparency. Preferably, the melting point of polyethylene terephthalate in the wear-resistant layer is 170~180°C; preferably, the thickness of the wear-resistant layer is 200~500µm.

To sum up, the stone plastic floor proposed by the present invention can use various types of discarded textile products as its materials, in order to reduce the waste caused by various textile products and the pollution to the environment; and uses materials that do not contain toxic ingredients and Materials that can be recycled repeatedly to reduce costs and are environmentally friendly to reduce the use of petrochemical materials, damage to the environment and waste of natural resources.

The following content will be combined with drawings to illustrate the technical content of the present invention through specific embodiments. Those familiar with this technology can easily understand other advantages and effects of the present invention from the content disclosed in this specification. The present invention can also be implemented or applied through other different specific embodiments. Various modifications and changes may be made to various details in this description based on different viewpoints and applications without departing from the spirit of the present invention.

Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meanings 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 construed to have definitions consistent with their meanings in the context of the relevant technology and the present invention, and are not to be construed as idealistic or overly formal meaning unless expressly so defined herein.

Please refer to Figure 1. Figure 1 is a schematic structural diagram of the stone plastic flooring of the present invention. The stone plastic floor 1 includes a base material layer 2, a first printing layer 4 disposed above the base material layer 2, and an anti-slip layer 3 disposed below the base material layer; the base material layer 2 mainly Contains plastic alloy and stone powder, and a variety of auxiliary agents such as compatibilizers, toughening agents, slip agents, water absorbing agents, and antioxidants; preferably, the thickness of the base material layer 2 is 4 to 8 mm; more preferably, the thickness of the base material layer 2 is 4 to 8 mm. The thickness of the base material layer 2 is 4.5mm. Among them, the plastic alloy includes polyethylene and polyethylene terephthalate, and its sources are mainly clothes, pants, shoes, hats, various types of backpacks, handbags and other waste fabrics. Preferably, based on the weight of the base material layer 2, the plastic alloy and the various auxiliary agents account for 35 to 55% in total; more preferably, the plastic alloy and the various auxiliary agents account for 40% in total. In addition, the content ratio of the polyethylene and the polyethylene terephthalate is 6:4 to 8:2; preferably, the polyethylene and the polyethylene terephthalate The content ratio is 7:3.

Optionally, the stone powder is selected from calcium carbonate, clay, montmorillonite, silica or talc. When the particle size of the stone powder is smaller, the coating of each component in the base material layer 2 is better; Preferably, the particle size of the stone powder is 300~1500 mesh; more preferably, due to cost considerations, the particle size of the stone powder is 300 mesh. Preferably, based on the weight of the base material layer 2, the stone powder accounts for 45 to 65%; more preferably, the stone powder accounts for 60%.

Optionally, the compatibilizer is selected from the group consisting of styrene-ethylene-butylene-styrene copolymer, styrene-butylene-styrene copolymer, ethylene propylene diene monomer rubber, polyethylene grafted maleic anhydride, polyethylene A group consisting of ethylene grafted with glycidyl methacrylate, polyolefin elastomer grafted with maleic anhydride or polyolefin elastomer grafted with glycidyl methacrylate. The compatibilizer utilizes its characteristics of being compatible with both polyethylene and polyethylene terephthalate to form a blend (i.e. plastic) of polyethylene, polyethylene terephthalate and the compatibilizer. alloy); preferably, based on the weight of the base material layer 2, the compatibilizer accounts for 2 to 6%; more preferably, the compatibilizer accounts for 4%.

Optionally, the toughening agent is selected from thermoplastic polyester elastomer or polyolefin elastomer; preferably, based on the weight of the base material layer 2, the toughening agent accounts for 8 to 12%; more preferably , the toughening agent accounts for 10%.

Optionally, the lubricant is selected from montan wax; preferably, the lubricant accounts for 0.3~0.7% based on the weight of the base material layer 2; more preferably, the lubricant accounts for 0.5%.

Optionally, the water absorbing agent is selected from calcium oxide powder; preferably, based on the weight of the base material layer 2, the water absorbing agent accounts for 3 to 7%; more preferably, the water absorbing agent accounts for 5%.

Optionally, the antioxidant is selected from pentaerythritol tetrakis (3,5-di-tert-butyl-4-hydroxy)phenylpropionate (Irganox ^® 1010); preferably, based on the weight of the substrate layer 2, The antioxidant accounts for 0.3~0.7%; more preferably, the antioxidant accounts for 0.5%.

The anti-slip layer 3 is composed of thermoplastic polyester elastomer. Preferably, the thickness of the anti-slip layer 3 is 1 to 5 mm; more preferably, the thickness of the anti-slip layer 3 is 2 mm. In addition, the thermoplastic polyester elastomer used in the anti-slip layer 3 can be further added with a foaming agent to micro-foam the thermoplastic polyester elastomer (slightly expand the volume), thereby reducing its specific gravity and thus having buffering and sound insulation effects; Preferably, the thermoplastic polyester elastomer used in the anti-slip layer 3 is added with a foaming agent to reduce the specific gravity to 0.4~0.6; even more preferably, the thermoplastic polyester elastomer used in the anti-slip layer 3 is added with a foaming agent. Then the proportion dropped to 0.4.

Referring also to Figure 2, Figure 2 is a schematic structural diagram of the first printing layer of the present invention. The first printing layer 4 is composed of a coating layer 41 and a pigment layer 42 . The coating layer 41 faces the base material layer 2 , and the pigment layer 42 is located above the coating layer 41 .

The coating layer 41 includes low-density polyethylene, polyolefin elastomer, ethylene-vinyl acetate copolymer or any combination thereof; preferably, the coating layer 41 is made of low-density polyethylene, polyolefin elastomer. , ethylene-vinyl acetate copolymer or any combination thereof, the melting point of the polymer is 90~140°C; more preferably, the coating layer 41 is selected from low-density polyethylene, polyolefin elastomer, ethylene-vinyl acetate The melting point of the copolymer or any combination thereof is 90~130°C. Preferably, the thickness of the coating layer 41 is 30~80µm.

The pigment layer 42 is composed of low melting point polyethylene terephthalate; preferably, the melting point of the low melting point polyethylene terephthalate is 130~170°C; preferably, the pigment The layer thickness is 30~50µm.

Please refer to Figure 3. Figure 3 is a schematic structural diagram of the stone plastic floor with the second printing layer of the present invention. In order to block the background color of the base material layer 2, a white second printing layer 5 can be further bonded between the base material layer 2 and the first printing layer 4; the second printing layer 5 The composition, melting point range and thickness are the same as those of the first printing layer 4 and will not be described again here.

Please refer to Figure 4. Figure 4 is a schematic structural diagram of the stone plastic floor with a wear-resistant layer of the present invention. In order to make the surface of the stone plastic floor 1 have better wear resistance, a wear-resistant layer 6 can be further provided above the first printing layer 4. The wear-resistant layer 6 is composed of polyethylene terephthalate. Ethylene terephthalate has a high crystallization rate, good optical transparency and wear resistance. Its wear resistance is twice that of ordinary polyvinyl chloride wear-resistant layers, so polyethylene terephthalate is selected as the wear-resistant layer. Layer 6. Preferably; the melting point of polyethylene terephthalate in the wear-resistant layer is 170~180°C; preferably, the thickness of the wear-resistant layer 6 is 200~500µm; more preferably, the wear-resistant layer Layer 6 thickness is 250µm.

Please refer to Figure 5. Figure 5 is a schematic structural diagram of the stone plastic floor with a wear-resistant layer and a second printing layer of the present invention. In order to block the background color of the base material layer 2 and make the surface of the stone plastic floor 1 have better wear resistance, another layer can be further bonded between the base material layer 2 and the first printing layer 4 at the same time. A white second printing layer 5 is provided, and a wear-resistant layer 6 is provided above the first printing layer.

Please refer to Figure 6, which is a schematic diagram of the preparation process of the stone plastic flooring of the present invention. It consists of the following steps:

Step S1: Place polyethylene, polyethylene terephthalate, stone powder and various auxiliary agents in a high-speed mixer to evenly mix and evaporate the water to form a first mixture;

Step S2: Place the first mixture in a twin-screw extruder for granulation to form base material layer pellets;

Step S3: Place the base material layer pellets and the thermoplastic polyester elastomer material as the anti-slip layer in a co-extrusion extruder for co-extrusion to obtain an integrally formed base material layer and anti-slip layer;

Step S4: Place the first printing layer on top of the base material layer, use a hot press laminating machine to laminate the first printing layer on top of the base material layer, and use a double roller flattening machine to flatten the first printing layer on top of the base material layer. On the base material layer, uncut stone plastic sheets are obtained;

Step S5: After cutting the uncut stone-plastic board into the required size, use a ditch washing machine to trim the periphery of the cut stone-plastic board, and then obtain the stone-plastic floor.

In step S1, the main sources of the polyethylene and the polyethylene terephthalate are clothes, pants, shoes, hats and various types of backpacks, handbags and other waste fabrics; preferably, the base is used Based on the weight of the material layer, the plastic alloy and the various auxiliary agents account for 35 to 55% in total; more preferably, the plastic alloy and the various auxiliary agents account for 40% in total. In addition, the content ratio of the polyethylene and the polyethylene terephthalate is 6:4 to 8:2; preferably, the polyethylene and the polyethylene terephthalate The content ratio is 7:3. The auxiliary agent system includes compatibilizer, toughening agent, lubricant, water absorbing agent and antioxidant.

Optionally, the stone powder is selected from calcium carbonate, clay, montmorillonite, silica or talc; preferably, the particle size of the stone powder is 300~1500 mesh; more preferably, due to cost considerations, the stone powder The particle size is 300 mesh. Preferably, based on the weight of the base material layer, the stone powder accounts for 45 to 65%; more preferably, the stone powder accounts for 60%.

Optionally, the compatibilizer is selected from the group consisting of styrene-ethylene-butylene-styrene copolymer, styrene-butylene-styrene copolymer, ethylene propylene diene monomer rubber, polyethylene grafted maleic anhydride, polyethylene A group consisting of ethylene grafted with glycidyl methacrylate, polyolefin elastomer grafted with maleic anhydride or polyolefin elastomer grafted with glycidyl methacrylate; preferably, based on the weight of the base material layer, The compatibilizer accounts for 2~6%; more preferably, the compatibilizer accounts for 4%.

Optionally, the toughening agent is selected from thermoplastic polyester elastomer or polyolefin elastomer; preferably, the toughening agent accounts for 8~12% based on the weight of the base material layer; more preferably, The toughening agent accounts for 10%.

Optionally, the lubricant is selected from montan wax; preferably, the lubricant accounts for 0.3~0.7% based on the weight of the base material layer; more preferably, the lubricant accounts for 0.5%.

Optionally, the water absorbing agent is selected from calcium oxide powder; preferably, the water absorbing agent accounts for 3 to 7% based on the weight of the substrate layer; more preferably, the water absorbing agent accounts for 5%.

Optionally, the antioxidant is selected from pentaerythritol tetrakis (3,5-di-tert-butyl-4-hydroxy)phenylpropanoate (Irganox ^® 1010); preferably, based on the weight of the substrate layer, The antioxidant accounts for 0.3~0.7%; more preferably, the antioxidant accounts for 0.5%.

In step S2, the screw length-to-diameter ratio of the twin-screw extruder is 48 to 56. When the screw length-to-diameter ratio is larger, the temperature segmentation can be increased to improve the mixability of each component in the first mixture. And gradually and slowly cool down; preferably, under the above-mentioned screw aspect ratio, the temperature segments can be 12 to 14 segments and gradually and slowly cool down, and the initial feeding temperature is 270°C. Since the one with the highest melting point in the first mixture is polyethylene terephthalate (250°C), the initial feeding temperature is set slightly higher than 250°C and gradually lowered to 270°C, so that all components are completely melted. Mix to improve the mixability of each ingredient.

In step S3, the co-extrusion extruder can be adjusted by the die screw at the outlet to set the thickness of the base material layer and the anti-slip layer, and maintain the base material layer at 150°C after co-extrusion. To facilitate subsequent lamination of the printing layer. Preferably, the thickness of the base material layer is 4~8mm; more preferably, the thickness of the base material layer is 4.5mm, and the thickness of the anti-slip layer is 1~5mm; more preferably, the thickness of the anti-slip layer Thickness is 2mm. In addition, in order to make the anti-slip layer have buffering and sound insulation effects, the thermoplastic polyester elastomer that can be used in the anti-slip layer can further add a foaming agent to make the thermoplastic polyester elastomer micro-foam (slightly expand in volume). ) to reduce its specific gravity; preferably, the thermoplastic polyester elastomer used in the anti-slip layer is added with a foaming agent to reduce the specific gravity to 0.4~0.6; more preferably, the thermoplastic polyester elastomer used in the anti-slip layer After adding foaming agent, the specific gravity dropped to 0.4.

In step S4, the first printing layer is composed of a coating layer and a pigment layer. The coating layer faces the base material layer, and the pigment layer is located above the coating layer.

The coating layer includes low-density polyethylene, polyolefin elastomer, ethylene-vinyl acetate copolymer or any combination thereof; preferably, the coating layer is selected from low-density polyethylene, polyolefin elastomer, ethylene -The melting point of vinyl acetate copolymer or any combination of polymers thereof is 90~140°C. Its melting point is lower than the temperature of 150°C maintained by the base material layer after co-extrusion in step S3, which can melt the printing layer and then fit it. On the base material layer; more preferably, the melting point of the low-density polyethylene, polyolefin elastomer, ethylene-vinyl acetate copolymer or any combination thereof selected for the coating layer is 90 to 130°C. Preferably, the thickness of the first printing layer is 30~80µm.

Furthermore, in order to block the background color of the base material layer, in step S4, a white second printing layer can be further bonded between the base material layer and the first printing layer; The composition, melting point range and thickness of the second printing layer are the same as those of the first printing layer, and will not be described again here.

In addition, in order to make the surface of the stone plastic floor have better wear resistance, in step S4, a wear-resistant layer can be further attached above the first printing layer. The wear-resistant layer is made of polyethylene terephthalate. Its wear resistance is twice that of ordinary PVC wear-resistant layers, and it has good optical transparency. Preferably, the melting point of polyethylene terephthalate in the wear-resistant layer is 170~180°C; preferably, the thickness of the wear-resistant layer is 200~500µm; more preferably, the wear-resistant layer Thickness is 250µm.

To sum up, the stone plastic floor proposed by the present invention can use various types of discarded textile products as its materials, in order to reduce the waste caused by various textile products and the pollution to the environment; and uses materials that do not contain toxic ingredients and Materials that can be recycled repeatedly to reduce costs and are environmentally friendly to reduce the use of petrochemical materials, damage to the environment and waste of natural resources. In addition, most of the stone plastic flooring materials used in the present invention are made of polyethylene and polyethylene terephthalate. In addition to having extremely high weather resistance, the materials can be fully recycled and directly crushed before being manufactured and reused. There is no need to go through tedious component separation steps, and the manufacturing cost can be reduced.

Those skilled in the art of the present invention can understand from the foregoing content that the present invention can be embodied in other specific forms without changing the technical concept or essential features of the present disclosure. In this regard, the illustrative aspects disclosed herein are for illustrative purposes only and should not be construed as limiting the scope of the disclosure. On the contrary, this disclosure is intended to cover not only the illustrative aspects, but also various alterations, modifications, equivalents, and alternatives that may be included within the spirit and scope of the invention as defined by the appended claims. Other forms.

1:Stone plastic floor 2: Base material layer 3: Anti-slip layer 4: First printing layer 41: Laminated layer 42:Pigment layer 5: Second printing layer 6: Wear-resistant layer S1~S5: steps

Figure 1 is a schematic structural diagram of the stone plastic flooring of the present invention; Figure 2 is a schematic structural diagram of the first printing layer of the present invention; Figure 3 is a schematic structural diagram of the stone plastic floor with the second printing layer of the present invention; Figure 4 is a schematic structural diagram of the stone plastic floor with a wear-resistant layer of the present invention; Figure 5 is a schematic structural diagram of the stone plastic floor with a wear-resistant layer and a second printing layer of the present invention; Figure 6 is a schematic diagram of the preparation process of the stone plastic flooring of the present invention.

1:Stone plastic floor

2: Base material layer

3: Anti-slip layer

4: First printing layer

Claims (11)

A kind of stone plastic floor, which contains: A base material layer, the thickness of the base material layer is 5~8mm; A first printing layer is provided above the base material layer. The first printing layer is composed of a coating layer and a pigment layer. The thickness of the coating layer is 30~80µm, and the thickness of the pigment layer is 30~50µm; and An anti-slip layer is provided below the base material layer. The thickness of the anti-slip layer is 1~5mm, wherein The base material layer includes plastic alloy, stone powder and a plurality of auxiliaries. The plastic alloy includes polyethylene and polyethylene terephthalate, and the sources of polyethylene and polyethylene terephthalate are clothing, For discarded fabrics such as pants, shoes, hats, and various backpacks and handbags, based on the weight of the base material layer, the plastic alloy and the plurality of auxiliary agents account for 35~55%, and the stone powder accounts for 45~65%; The coating layer contains low-density polyethylene, polyolefin elastomer, ethylene-vinyl acetate copolymer or any combination thereof; The pigment layer consists of low-melting polyethylene terephthalate; and The anti-slip layer is composed of thermoplastic polyester elastomer. The stone plastic floor as described in claim 1, wherein the plurality of auxiliary agents include: Compatibilizer, the compatibilizer is selected from styrene-ethylene-butylene-styrene copolymer, styrene-butylene-styrene copolymer, EPDM rubber, polyethylene grafted maleic anhydride, polyethylene A group consisting of grafted glycidyl methacrylate, polyolefin elastomer grafted with maleic anhydride, or polyolefin elastomer grafted with glycidyl methacrylate; Toughening agent, the toughening agent is selected from thermoplastic polyester elastomer or polyolefin elastomer; Lubricant, the lubricant is montan wax; Water absorbing agent, the water absorbing agent is calcium oxide powder; and Antioxidant, the antioxidant is pentaerythritol tetrakis (3,5-di-tert-butyl-4-hydroxy)phenylpropionate, wherein Based on the weight of the base material layer, the compatibilizer accounts for 2~6%, the toughening agent accounts for 8~12%, the lubricant accounts for 0.3~0.7%, the water absorbing agent accounts for 3~7%, and the antioxidant accounts for 0.3~0.7%. The stone plastic flooring as described in claim 1, wherein the stone powder is selected from calcium carbonate, clay, montmorillonite, silica or talc, and the particle size of the stone powder is 300~1500 mesh. The stone plastic flooring as described in claim 1, wherein the thermoplastic polyester elastomer used in the anti-slip layer is further added with a foaming agent to reduce its specific gravity to 0.4~0.6. The stone plastic flooring according to claim 1, wherein a second printing layer is further included between the base material layer and the first printing layer, and the second printing layer is also composed of a coating layer and a pigment layer. The thickness of the coating layer is 30~80µm, the thickness of the pigment layer is 30~50µm, and the coating layer contains low density polyethylene, polyolefin elastomer, ethylene-vinyl acetate copolymer or any combination thereof, the pigment layer is composed of Composed of low melting point polyethylene terephthalate. The stone plastic flooring according to claim 5, wherein the melting point of the coating layer in the first printing layer and the second printing layer is 90~140°C. The stone plastic flooring according to claim 1 or claim 5, wherein a wear-resistant layer is further provided above the first printing layer, the thickness of the wear-resistant layer is 200~500µm, and the wear-resistant layer is made of polyterephthalate Composed of ethylene glycol. A method for preparing stone plastic flooring as described in any one of claims 1 to 7, which includes the following steps: Step S1: Place polyethylene, polyethylene terephthalate, stone powder and a plurality of auxiliary agents in a high-speed mixer to evenly mix and evaporate the water to form a first mixture; Step S2: Place the first mixture in a twin-screw extruder for granulation to form base material layer pellets; Step S3: Place the base material layer pellets and the thermoplastic polyester elastomer material as an anti-slip layer in a co-extrusion machine for co-extrusion to obtain an integrally formed base material layer and an anti-slip layer; Step S4: Place a first printing layer on top of the base material layer, use a hot press laminating machine to laminate the first printing layer on top of the base material layer, and use a pair of roller flatteners to laminate the first printing layer. The layer is flatly attached to the base material layer to obtain an uncut stone plastic plate; Step S5: After cutting the uncut stone-plastic board into the required size, use a ditch washing machine to trim the periphery of the cut stone-plastic board, and then obtain the stone-plastic floor. The preparation method of stone plastic flooring as described in claim 8, wherein in step S2, the screw length-to-diameter ratio of the twin-screw extruder is 48~56, and the temperature section of the twin-screw extruder is 12~ Section 14, the initial feeding temperature is 270°C. The preparation method of stone plastic flooring as described in claim 8, wherein in step S3, after co-extrusion, the base material layer is maintained at 150°C. The preparation method of stone plastic flooring as described in claim 8, wherein in step S4, a second printing layer is further bonded between the base material layer and the first printing layer and/or the first printing layer is further bonded A wear-resistant layer is attached above the printing layer.

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