WO2017121389A1 - 一种复合地板 - Google Patents

一种复合地板 Download PDF

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Publication number
WO2017121389A1
WO2017121389A1 PCT/CN2017/071155 CN2017071155W WO2017121389A1 WO 2017121389 A1 WO2017121389 A1 WO 2017121389A1 CN 2017071155 W CN2017071155 W CN 2017071155W WO 2017121389 A1 WO2017121389 A1 WO 2017121389A1
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WO
WIPO (PCT)
Prior art keywords
parts
composite
layer
functional layer
glue
Prior art date
Application number
PCT/CN2017/071155
Other languages
English (en)
French (fr)
Inventor
刘辉煌
黄荣泰
刘东岳
刘国俊
Original Assignee
上海协承昌化工有限公司
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by 上海协承昌化工有限公司 filed Critical 上海协承昌化工有限公司
Publication of WO2017121389A1 publication Critical patent/WO2017121389A1/zh

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    • B44C5/043—Ornamental plaques, e.g. decorative panels, decorative veneers containing wooden elements
    • C—CHEMISTRY; METALLURGY
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Definitions

  • the invention belongs to the field of building materials, in particular to a composite board.
  • the traditional wooden floor is mostly solid floor
  • the use of solid wood floor will consume a lot of wood, resulting in environmental damage, and the cost of the floor is also high. Therefore, it is very necessary to seek alternatives to existing solid wood flooring.
  • Polyvinyl chloride one of the most widely used general-purpose plastics, has long been used in the field of building materials, for example as sheet or pipe.
  • PVC sheets In the field of sheet metal, commonly used PVC sheets include rigid PVC and soft PVC.
  • the plasticizer content of the two is different, which causes the properties of the two to be different.
  • the former has a plasticizer content of less than 10%, while the latter increases.
  • the plasticizer content is 30 ⁇ 70%.
  • Plasticizers are industrially widely used polymeric material auxiliaries. Adding this material to plastic processing can enhance flexibility and ease of processing. Plasticizers generally include aliphatic dibasic acid esters, phthalic acid esters, benzene polyesters, benzoic acid esters, polyhydric alcohol esters, chlorinated hydrocarbons, and epoxy resins. , citric acid esters, polyesters and the like. Among them, the most commonly used plasticizers are phthalates or phthalates, such as di(2-ethylhexyl) phthalate (DEHP), dibutyl phthalate (DBP). )Wait. Plasticizers have certain toxicity to the human body, and will gradually escape from PVC materials with long-term use, which has an impact on human health. Due to the low content of plasticizer in rigid PVC, it is healthier and more environmentally friendly than soft PVC, and can be used as an interior decorative board for a long time.
  • DEHP di(2-ethylhexyl) phthalate
  • Hard PVC sheets are also highly flame-retardant, non-absorbent, and reusable. Therefore, they have a wide range of applications in the field of building materials, especially in the field of panels.
  • the conventional rigid PVC also has obvious disadvantages, such as high hardness, and it is insufficient in comfort when used as a board, especially a floor, and there is still a possibility of slight deformation.
  • the traditional hard PVC color is single and the visual effect is poor.
  • the object of the present invention is to provide a composite panel which is relatively healthy and environmentally friendly, comfortable to the touch, visually pleasing, and extremely resistant to deformation.
  • the composite sheet of the invention can also be processed according to actual needs to achieve greater functionality and utility.
  • the technical solution adopted by the present invention is: a composite board comprising a substrate board and an upper surface functional layer covering the upper surface of the substrate board.
  • the components of the substrate sheet comprise stone powder, glass powder, glass sand, glass slag or wood chips, and plastic.
  • the plasticizer is present in the substrate sheet in an amount of less than 10% or no plasticizer.
  • the plastic is PVC.
  • the composition of the substrate sheet comprises: 100 parts by weight of PVC, one or more of 210 to 270 parts of stone powder, glass powder, glass sand, glass slag or wood chips.
  • the substrate sheet is formed from the following components by weight: PVC 100 parts, stone powder, glass powder, glass sand, glass slag or wood chips 210 ⁇ 270 parts, stabilizer 2 ⁇ 6 parts, stearic acid 0.2 ⁇ 0.8 parts, PE wax 0.2 ⁇ 0.8 parts, chlorinated polyethylene 1 ⁇ 5 parts 0.5 ⁇ 2 parts of ACR modifier, 1 ⁇ 5 parts of titanium dioxide and 0.01 ⁇ 0.05 parts of OB-1 whitening agent.
  • the substrate sheet is formed from the following components by weight: PVC 100 parts, 240 parts of stone powder or wood chips, 4 parts of stabilizer, 0.5 parts of stearic acid, 0.5 parts of PE wax, 3 parts of chlorinated polyethylene, 1 part of ACR modifier, 3 parts of titanium dioxide, OB-1 brightener 0.03 parts.
  • the composition of the substrate sheet comprises: 100 parts by weight of PVC, 50-80 parts of perlite, 210-270 parts of stone powder or wood chips.
  • the substrate sheet is formed from the following components by weight: PVC 100 parts, 50 ⁇ 80 parts of perlite, 160 ⁇ 190 parts of stone powder or wood chips, 2 ⁇ 6 parts of stabilizer, 0.2 ⁇ 0.8 parts of stearic acid, 0.2 ⁇ 0.8 parts of PE wax, 1 ⁇ 5 parts of chlorinated polyethylene, ACR 0.5 ⁇ 2 parts of modifier, 1 ⁇ 5 parts of titanium dioxide and 0.01 ⁇ 0.05 parts of OB-1 whitening agent.
  • the substrate sheet is formed from the following components by weight: PVC 100 parts, 65 parts of perlite, 175 parts of stone powder or wood chips, 4 parts of stabilizer, 0.5 parts of stearic acid, 0.5 parts of PE wax, 5 parts of chlorinated polyethylene, 1 part of ACR modifier, 3 parts of titanium dioxide, OB -1 whitening agent 0.03 parts.
  • the upper surface functional layer is one of a veneer, a bamboo-wood composite board, a calcium carbonate board, a calcium silicate board, a gypsum board, a plexiglass, a metal plate, a plastic plate, and a foam board.
  • the metal plate is one of a galvanized plate and a 0.1 to 0.5 mm steel plate.
  • the substrate plate has a thickness of 0.2 to 30 mm, and the upper surface functional layer has a thickness of 0.1 to 15 mm.
  • the substrate plate has a thickness of 1 to 20 mm, and the upper surface functional layer has a thickness of 0.5 to 5 mm.
  • the upper surface functional layer and the substrate layer are bonded by an adhesive
  • the adhesive is AB glue, epoxy resin adhesive, phenolic resin glue, polyurethane glue, acrylate glue, PES polyester glue, One or more of PA polyamide glue, PE polyethylene glue, EVA ethylene vinyl acetate copolymer glue, styrene and its block copolymer hot melt adhesive, urea formaldehyde resin glue, pressure sensitive adhesive or alcoholate glue .
  • the method for preparing the composite sheet further comprises: enhancing adhesion between the upper surface functional layer and the substrate layer by cold pressing.
  • the cold pressing is carried out at normal temperature.
  • the cold pressing pressure is 8 to 12 kg/cm 2 .
  • the cold pressing time is 40 to 60 min.
  • the composite sheet further comprises a paint film protective layer covering the upper surface of the upper surface functional layer.
  • the paint film protective layer is formed by roll coating or shower coating a UV coating on the upper surface of the upper surface functional layer.
  • the protective layer of the paint film has a thickness of 0.08 to 0.25 mm.
  • the protective layer of the paint film has a thickness of 0.12 to 0.18 mm.
  • the paint film protective layer contains alumina particles or silicon carbide particles having a particle diameter of 20 to 300 ⁇ m.
  • the paint film protective layer contains alumina particles or silicon carbide particles having a particle diameter of 75 to 200 ⁇ m.
  • the alumina particles or corundum particles are at least partially embedded in the UV coating.
  • the specific preparation steps of the paint film protective layer include:
  • the composite sheet further comprises a lower surface functional layer covering the lower surface of the substrate sheet.
  • the lower surface functional layer is one of wood board, veneer, bamboo wood composite board, calcium carbonate board, calcium silicate board, gypsum board, plexiglass, metal board, plastic board, foam board.
  • the metal plate is one of a galvanized plate and a 0.1 to 0.5 mm steel plate.
  • the wood board or composite board is bonded to the substrate layer by a second adhesive, and the lower surface functional layer is bonded to the substrate layer by an adhesive
  • the adhesive is AB glue, epoxy Resin adhesive, phenolic resin glue, polyurethane glue, acrylate glue, PES polyester glue, PA polyamide glue, PE polyethylene glue, EVA ethylene vinyl acetate copolymer glue, styrene and its block copolymer hot melt adhesive, One or more of urea-formaldehyde resin glue, pressure-sensitive adhesive or alcoholate glue.
  • the composite sheet further includes an adhesive layer covering the lower surface of the lower surface functional layer.
  • the adhesive layer is water-based acrylate pressure sensitive adhesive, water-based polyurethane pressure sensitive adhesive, solvent-based rubber pressure sensitive adhesive, solvent-based acrylate pressure sensitive adhesive, emulsion rubber pressure sensitive adhesive, emulsion acrylate One of pressure sensitive adhesive or UV adhesive.
  • the UV glue consists of the following mass percentages of raw materials:
  • oligomer 30-50% oligomer, 40-60% active monomer, 3-10% photoinitiator, 1-10% auxiliary;
  • the oligomer is one or more of urethane acrylate, polybutadiene acrylate, epoxy acrylate, pure acrylic resin, polyester acrylate;
  • the reactive monomer is one or more of a monofunctional, difunctional, polyfunctional acrylate
  • the photoinitiator is one or more of a free radical photoinitiator.
  • the UV glue consists of the following mass percentages of raw materials:
  • the monofunctional acrylate is isobornyl methacrylate, isobornyl acrylate or 2 (2-ethoxyethoxy)ethyl acrylate;
  • the difunctional acrylate is tripropylene glycol diacrylate, 1. 6-hexanediol diacrylate or tricyclodecane dimethanol diacrylate;
  • the polyfunctional acrylate reactive monomer is one or more of trimethylolpropane triacrylate, trimethylolpropane triacrylate, pentaerythritol triacrylate, and dipentaerythritol hexaacrylate.
  • the auxiliary agent is one or more of an adhesion promoter, an antifoaming agent, a leveling agent, a wetting agent, and an antioxidant.
  • the adhesion promoter is a silane coupling agent Y-glycidyloxypropyltrimethoxysilane, Y-aminopropyltriethoxysilane, Y-methacryloxypropyltrimethyl Oxysilane, Y-methacryloxypropyltriethoxysilane, N-(B-aminoethyl)-Y - one or more of aminopropyltrimethoxysilane and acrylate phosphate 2-hydroxyethyl methacrylate phosphate, methacrylic acid phosphate;
  • the antifoaming agent is a silicone antifoaming agent
  • the leveling agent is a silicone leveling agent
  • the wetting agent is a modified polydimethylsiloxane
  • the antioxidant is a hindered phenolic antioxidant.
  • the adjuvant is polyethylene glycol 2000.
  • the photoinitiator is 2 hydroxy-2-methyl-1-phenyl-1-propanone, 1-hydroxy-cyclohexyl benzophenone, 2,4,6-trimethylbenzoyl-di Phenylphosphine oxide, bis(2,4,6-trimethylbenzoyl)phenylphosphine oxide, 2,4,6-trimethylbenzophenone, 4-methylbenzophenone, 2- Phenylbenzyl-2-dimethylamine-1- One or more of (4-morpholinium phenyl) butanone.
  • the substrate board or the composite board is provided with a buckle, and the upper surface functional layer is chamfered.
  • the method for preparing the composite sheet further comprises: enhancing adhesion between the upper and lower surface functional layers and the substrate layer by means of hot pressing.
  • a layer of release film is further included below the adhesive layer.
  • the composite sheet provided by the invention can select a suitable upper surface functional layer according to actual needs, which can save resources, and has stronger functionality and practicability.
  • the composite sheet provided by the present invention comprises a substrate sheet and an upper surface functional layer covering the upper surface of the substrate sheet.
  • the upper surface functional layer covering the surface of the substrate sheet can be selected according to the actual needs of the touch, visual effects and functional effects of the sheet.
  • a plate made of a natural material such as a veneer or a bamboo-wood composite board may be used.
  • a metal plate such as a stainless steel plate, an aluminum alloy plate or a titanium alloy plate can be used.
  • a foam board can be used.
  • calcium carbonate board, calcium silicate board or gypsum board can be selected.
  • a plexiglass plate is also available.
  • plastics such as soft PVC sheets can be used.
  • soft PVC is also included, it is more environmentally friendly than simply using soft PVC sheets.
  • the skin layer of the invention is located on the surface of the board, provides the touch, visual effect and functional effect required of the board, and is flexible and adaptable to different needs.
  • the materials selected are relatively expensive, such as the selection of metal plates, the use of inexpensive hard PVC substrates instead of pure metal plates can not only greatly reduce the cost and weight of the plates, but also maintain the tactile and visual effects of the metal sheets.
  • the substrate board and the upper surface functional layer can be bonded by an adhesive
  • the adhesive is a polymer adhesive suitable for rigid PVC, such as AB glue, epoxy resin adhesive or urea-formaldehyde resin glue.
  • an adhesive having a strong bonding force with both the substrate and the skin layer should be used.
  • acrylic, epoxy or polyurethane AB adhesives have wide applicability and can be used for bonding plastics and plastics, plastics and metals, metals and metals.
  • Polyurethane adhesive suitable for bonding PVC, TPR, rubber, nylon cloth, ABS, synthetic leather and other PU cooperation materials.
  • the Applicant has unexpectedly discovered that it is additionally possible to supplement the bonding between the substrate sheet and the upper surface functional layer by means of hot pressing or cold pressing.
  • the substrate plate and the upper surface functional layer may even be bonded without being bonded by an adhesive, but by coextrusion or hot pressing.
  • the upper surface functional layer is made of a soft PVC board, it can be bonded without using an adhesive and using only hot pressing or co-extrusion. In this case, the two materials are partially fused together at the interface due to heat fusion, and the sticking effect is even better than the use of the binder when the conditions are controlled.
  • the sheet material of the present invention covers the surface of the substrate sheet with the upper surface functional layer, and the adhesive portion can be omitted compared with the surface processing of the conventional PVC sheet material.
  • PVC generally has poor adhesion to surface-modifying materials (such as paint).
  • the sheet of the present invention covers the upper surface functional layer on the surface of the PVC, thereby transferring the surface modification onto the upper surface functional layer, and the material of the upper surface functional layer generally has better bonding to the surface modifying material without requiring adhesion. Therefore, the close connection of the traditional PVC sheet is omitted.
  • the composite sheet of the present invention may further include a lower surface functional layer and other layers under the substrate sheet, such as a mat layer or an adhesive layer, and the mat layer is attached to the substrate.
  • a lower surface functional layer and other layers under the substrate sheet such as a mat layer or an adhesive layer
  • the mat layer is attached to the substrate.
  • the mat can provide a more comfortable foot feel, a quieter effect and better ground compatibility.
  • the edges of the substrate panels may have snaps that facilitate the connection between the panels.
  • the latches can take the form conventionally used in the art, such as the various latching forms disclosed in the patents WO2015118451A1, CN102051973A, CN103932510A, CN104619936A, CN104854286A, US9193137B2.
  • further processing may be performed on the upper surface of the upper surface functional layer, for example, by brush abrasion treatment, so that the sheet of the present invention has wider functionality and satisfies the user. Personalized needs.
  • the composite sheet in this embodiment comprises a substrate sheet and an upper surface functional layer covering the upper surface of the substrate sheet, wherein the upper surface functional layer and the substrate layer are bonded by an adhesive, wherein the substrate sheet is a PVC substrate.
  • the material layer on the upper surface is a veneer functional layer.
  • the PVC substrate sheet is formed from the following components by weight: PVC 100 parts, 240 parts of wood chips, 4 parts of stabilizer, 0.5 parts of stearic acid, 0.5 parts of PE wax, 3 parts of chlorinated polyethylene, 1 part of ACR modifier, 3 parts of titanium dioxide, 0.03 parts of OB-1 whitening agent .
  • PVC, stabilizer, stearic acid, PE wax, chlorinated polyethylene, ACR modifier, titanium dioxide, OB-1 brightener are all common industrial raw materials.
  • the particle size of the wood chips is 0.1 ⁇ 2mm, and the wood chips of various woods can be used, preferably white oak wood chips.
  • the extrusion process step of the PVC substrate sheet of the present embodiment is: mixing the above raw materials at 40 ° C with uniform mixing; after the stirring is completed, transferring the materials to an extruder and heating to 150-160 ° C, The size of the nip is adjusted according to the thickness required for processing. After being fully plasticized by the screw, it is extruded into a single layer slab through a narrow nose. After further cooling by the three-roll calender, after a certain distance of the guide roller is further cooled, the edge can be wound and formed.
  • the thickness of the substrate sheet prepared in this embodiment can be adjusted according to actual needs. Generally, the substrate thickness of the substrate can be adjusted to 0.2 to 30 mm, and the more commonly used thickness is 1 to 20 mm.
  • the substrate sheet prepared in this embodiment has a Shore D hardness of about 70, a heat curl of as low as ⁇ 1.2 mm, a change in water absorption quality of as low as ⁇ 0.5%, and a boiling resistance of 5 grades.
  • the substrate sheet prepared in this embodiment does not contain a plasticizer, which is beneficial to environmental protection and human health.
  • a plasticizer which is beneficial to environmental protection and human health.
  • a certain amount of plasticizer can be added according to actual needs, and the mass percentage of the plasticizer should not exceed 10%.
  • the veneer functional layer is made of white oak skin, and the thickness of the veneer functional layer is 0.1 ⁇ 2.0. Mm is OK, more commonly used is 0.5 ⁇ 5mm.
  • the adhesive is made of conventional polyurethane hot melt adhesive. The specific production method includes the following steps:
  • step b uniformly coating the upper surface of the cleaned PVC substrate sheet in step a with a polyurethane hot melt adhesive
  • the lock can be opened on the PVC substrate board (for example, refer to application number 201380055155.9, the invention name is "composite waterproof floor and wall"
  • the method disclosed in the Chinese patent application for the cover plate is unlocked. It is also possible to chamfer the upper surface functional layer.
  • the composite board prepared in this embodiment adopts the PVC substrate board to stick the veneer functional layer, which not only saves the wood, but also achieves the same effect as the solid wood floor. Since the veneer itself has a good adhesion to the paint, it is not necessary to perform an additional adhesion treatment on the surface of the rigid PVC substrate like a conventional PVC sheet.
  • the veneer functional layer may also be a bamboo-wood composite board.
  • the veneer functional layer can also be replaced with a metal plate or a foam board, and no wood chips are used in the raw material of the PVC substrate board. If a metal plate is used, a certain amount of plasticizer may be appropriately added in order to increase the comfort of the pedaling; if a foam board is used, it is not necessary to add a plasticizer.
  • the composite sheet in this embodiment comprises a substrate sheet, an upper surface functional layer covering the upper surface of the substrate sheet, a paint film protective layer covering the upper surface of the upper surface functional layer, and an upper surface functional layer and a substrate layer.
  • Adhesive bonding is used to form a protective film of the film by rolling a UV coating onto the upper surface of the upper surface functional layer.
  • the substrate board is a PVC substrate board
  • the upper surface functional layer is a veneer functional layer
  • the main function of the paint film protective layer is to enhance wear resistance.
  • the paint film protective layer comprises a wear-resistant powder layer, a wear-resistant powder layer, and alumina particles.
  • the raw materials of the wear-resistant powder layer include: aminoacrylic resin 70%, auxiliary agent 0.1%, diluent acrylate 5%, filler 15%, photoinitiator ⁇ -hydroxyketone 0.01% or more, all of which are weight percentages.
  • the agent includes a leveling agent, an antifoaming agent, a binder, a wetting agent, and an inhibitor.
  • the above raw materials are all industrial raw materials.
  • the raw materials of the wear-resistant powder coating layer include: polyether acrylic resin 60%, auxiliary agent 0.4%, thinner polyacrylate 20%, filler 19.5% and photoinitiator aminoketone 0.1%, wherein the auxiliary agent includes a leveling agent, A foaming agent, a binder, a wetting agent, and an inhibitor.
  • the above raw materials are all industrial raw materials.
  • the alumina particles may have an average particle diameter of 20 to 300 ⁇ m, more preferably 75 to 200 ⁇ m.
  • the process of applying the protective layer of the paint film is:
  • step b) sequentially adding photoinitiator active amine, diluent acrylate and auxiliary agent to the liquid epoxy acrylic resin obtained in step a), in 20 ⁇ 40 R/s stirring at a constant speed until uniform, to obtain a wear-resistant powder coating;
  • step c) applying the wear-resistant powder coating layer obtained in the step b) to the upper surface of the veneer functional layer of the plate prepared in the step 2) using a roll coater to obtain a wear-resistant powder layer, during the roll coating process, the conveyor belt
  • the speed is set to 5-20m/min;
  • step d) curing and drying the coating obtained in step d) using an ultraviolet lamp
  • the parameters of curing and drying are set as follows: the speed of the conveyor belt is 5-20 m/min; the height of the ultraviolet lamp from the conveyor belt is 10-35 cm;
  • the wear-resistant powder coating on the wear-resistant powder by roller coating; curing and drying the wear-resistant coating layer by using an ultraviolet lamp, and setting the curing drying parameter to be: the speed of the conveyor belt is 5-20 m/min; The height of the light from the conveyor belt is 10-35 cm.
  • the thickness of the paint film protective layer may be controlled to be 0.08 to 0.25 mm as needed, and more preferably controlled to be 0.12 to 0.18 mm.
  • the wear resistance layer of the embodiment has an increased wear resistance coefficient, and the wear resistance effect is significantly increased:
  • the conforming floor prepared in Example 1 is: S-33 abrasive cloth strip, the standard is ⁇ 0.08g/100r; 1000 rpm wear standard;
  • the composite floor prepared in this embodiment S-33 abrasive cloth strip, standard ⁇ 0.08g/100r; 2000 rpm wear standard.
  • the lock can be opened on the PVC substrate board (for example, refer to application number 201380055155.9, the invention name is "composite waterproof floor and wall"
  • the method disclosed in the Chinese patent application of the cover plate can also be chamfered on the upper surface functional layer.
  • the alumina particles can also be replaced with corundum particles.
  • the composite sheet in this embodiment comprises a substrate sheet, an upper surface functional layer covering the upper surface of the substrate sheet, a paint film protective layer covering the upper surface of the upper surface functional layer, and a lower surface covering the substrate sheet.
  • the lower surface functional layer, the adhesive layer covering the lower surface of the lower surface functional layer, the upper surface functional layer and the lower surface functional layer and the substrate layer are bonded by an adhesive, and the paint film protective layer is coated by spraying the UV coating Formed on the upper surface of the upper surface functional layer.
  • the substrate plate is a PVC substrate plate
  • the upper surface functional layer and the lower surface functional layer are veneer functional layers
  • the main function of the paint film protective layer is to enhance wear resistance.
  • the adhesive layer mainly uses UV pressure sensitive adhesive, and the specific steps are as follows:
  • the composite sheet in this embodiment also provides a lower surface wood board functional layer because the lower surface wood board functional layer is also bonded to the PVC substrate board with an adhesive, which can improve the pedaling. comfortability.
  • the wood board used for the lower surface functional layer can be made of various woods because it is not visible to the user and does not require the appearance quality of the wood board. The softer wooden board can further improve the comfort of pedaling.
  • the wood board used for the lower surface functional layer can also be replaced by various composite boards.
  • the lower surface functional layer can also be directly coated with an adhesive (for example, UV glue), and no additional functional layer is attached.
  • the composite sheet with the adhesive layer can be greatly facilitated during installation. Only the release film on the lower surface of the adhesive layer needs to be torn off during the construction, and then the composite floor can be directly attached to the ground.
  • the adhesive layer is applied to the lower surface of the lower surface functional layer.
  • the adhesive layer may be directly attached to the lower surface of the PVC substrate without using the lower surface functional layer.
  • the UV pressure sensitive adhesive may also be replaced with an aqueous pressure sensitive adhesive or an emulsion type pressure sensitive adhesive.
  • an aqueous pressure sensitive adhesive or an emulsion type pressure sensitive adhesive is used, a photocuring step is not required for preparation.
  • the composite sheet in this embodiment comprises a substrate sheet and an upper surface functional layer covering the upper surface of the substrate sheet, wherein the upper surface functional layer and the substrate layer are bonded by an adhesive, wherein the substrate sheet is a PVC substrate.
  • the upper surface functional layer is a calcium silicate board.
  • the PVC substrate sheet is formed from the following components by weight: PVC 100 parts, 240 parts of stone powder, 4 parts of stabilizer, 0.5 parts of stearic acid, 0.5 parts of PE wax, 3 parts of chlorinated polyethylene, 1 part of ACR modifier, 3 parts of titanium dioxide, 0.03 parts of OB-1 whitening agent .
  • PVC, stabilizer, stearic acid, PE wax, chlorinated polyethylene, ACR modifier, titanium dioxide, OB-1 brightener are all common industrial raw materials.
  • the particle size of the stone powder is 0.01 ⁇ 0.5mm, and various commonly used industrial stone powders are available, preferably calcium carbonate powder.
  • the extrusion process step of the PVC substrate sheet of the present embodiment is: mixing the above raw materials at 40 ° C with uniform mixing; after the stirring is completed, transferring the materials to an extruder and heating to 150-160 ° C, The size of the nip is adjusted according to the thickness required for processing. After being fully plasticized by the screw, it is extruded into a single layer slab through a narrow nose. After further cooling by the three-roll calender, after a certain distance of the guide roller is further cooled, the edge can be wound and formed.
  • the thickness of the substrate sheet prepared in this embodiment can be adjusted according to actual needs. Generally, the substrate thickness of the substrate can be adjusted to 0.2 to 30 mm, and the more commonly used thickness is 1 to 20 mm.
  • the substrate hardness obtained by the present embodiment has a Shore D of about 83, a thermal curl of as low as ⁇ 1.4 mm, a change in water absorption quality of as low as ⁇ 0.5%, and a boiling resistance of 5 grades.
  • the substrate sheet prepared in this embodiment does not contain a plasticizer, which is beneficial to environmental protection and human health.
  • a plasticizer which is beneficial to environmental protection and human health.
  • a certain amount of plasticizer can be added according to actual needs, and the mass percentage of the plasticizer should not exceed 10%.
  • the thickness of calcium silicate board is 0.1 ⁇ 2.0 Mm is OK, more commonly used is 0.5 ⁇ 5mm.
  • Adhesive is selected from AB glue.
  • the specific production method using AB glue is:
  • step b uniformly coating a layer of A glue or B on the upper surface of the cleaned PVC substrate in step a, and uniformly coating a layer of B glue or A glue on the lower surface of the calcium silicate board;
  • the above step b may also be that the A glue and the B glue are uniformly mixed in an equal volume, and the mixed A glue and B glue are uniformly applied to the upper surface of the PVC substrate board and/or the silicic acid within 3 minutes.
  • the lower surface of the calcium plate is then immediately subjected to the above step C.
  • AB glue can also be replaced with epoxy adhesive.
  • the lock can be opened on the PVC substrate board (for example, refer to application number 201380055155.9, the invention name is "composite waterproof floor and wall"
  • the method disclosed in the Chinese patent application of the cover plate can also be chamfered on the upper surface functional layer.
  • the composite floor prepared in this embodiment adopts a PVC substrate plate with a calcium silicate board, which not only saves the stone, but also achieves the same effect as the stone floor.
  • the calcium silicate board can also be replaced with a calcium carbonate board, a gypsum board, or an organic glass.
  • the composite sheet in this embodiment comprises a substrate sheet and an upper surface functional layer covering the upper surface of the substrate sheet, wherein the upper surface functional layer and the substrate layer are bonded by an adhesive, wherein the substrate sheet is a PVC substrate.
  • the upper surface functional layer is a soft PVC board.
  • the PVC substrate sheet is formed from the following components by weight: PVC 100 parts, 4 parts of stabilizer, 0.5 part of stearic acid, 0.5 part of PE wax, 3 parts of chlorinated polyethylene, 1 part of ACR modifier, 3 parts of titanium dioxide, 0.03 parts of OB-1 whitening agent.
  • PVC polyvinyl ethylene
  • stabilizer 0.5 part of stearic acid
  • PE wax 0.5 part of PE wax
  • chlorinated polyethylene 1 part of ACR modifier
  • titanium dioxide 0.03 parts of OB-1 whitening agent.
  • PVC, stabilizer, stearic acid, PE wax, chlorinated polyethylene, ACR modifier, titanium dioxide, OB-1 brightener are all common industrial raw materials.
  • the extrusion process step of the PVC substrate sheet of the present embodiment is: mixing the above raw materials at 40 ° C with uniform mixing; after the stirring is completed, transferring the materials to an extruder and heating to 150-160 ° C, The size of the nip is adjusted according to the thickness required for processing. After being fully plasticized by the screw, it is extruded into a single layer slab through a narrow nose. After further cooling by the three-roll calender, after a certain distance of the guide roller is further cooled, the edge can be wound and formed.
  • the thickness of the substrate sheet prepared in this embodiment can be adjusted according to actual needs. Generally, the substrate thickness of the substrate can be adjusted to 0.2 to 30 mm, and the more commonly used thickness is 1 to 20 mm.
  • the substrate hardness obtained by the present embodiment has a Shore D of about 83, a thermal curl of as low as ⁇ 0.8 mm, a change in water absorption quality of as low as ⁇ 0.5%, and a boiling resistance of 5 grades.
  • the substrate plate prepared in this embodiment does not contain a plasticizer, which is beneficial to environmental protection and human health.
  • the difference between the composition of the soft PVC board and the PVC substrate board is that a plasticizer with a mass percentage of 5% to 10% is added on the basis of the composition of the PVC substrate sheet, and the thickness of the soft PVC board is 0.1. ⁇ 2.0 Mm is OK, more commonly used is 0.5 ⁇ 5mm.
  • the soft PVC sheet in this embodiment may also be used to coextrude a rigid PVC substrate sheet and a soft PVC sheet to form a two-layer structure without using an adhesive.
  • the lock can be opened on the PVC substrate board (for example, refer to application number 201380055155.9, the invention name is "composite waterproof floor and wall"
  • the method disclosed in the Chinese patent application of the cover plate is opened and chamfered on the upper surface functional layer.
  • the composite of this embodiment combines the advantages of both rigid PVC and soft PVC.
  • the rigid PVC provides the sheet with stronger strength and less plasticizer content, while the soft PVC makes up the hard PVC. Poor shortcomings.
  • the composite sheet in this embodiment comprises a substrate sheet and an upper surface functional layer covering the upper surface of the substrate sheet, wherein the upper surface functional layer and the substrate layer are bonded by an adhesive, wherein the substrate sheet is a PVC substrate.
  • the upper surface functional layer is a plexiglass plate.
  • the preparation method was the same as in Example 1.
  • the thickness of the plexiglass plate is 0.1 ⁇ 2.0 Mm is OK, more commonly used is 0.5 ⁇ 5mm.
  • the adhesive is made of acrylate adhesive. The specific production method includes the following steps:
  • step b uniformly coating the upper surface of the cleaned PVC substrate sheet in step a with acrylate glue
  • the lock can be opened on the PVC substrate board (for example, refer to application number 201380055155.9, the invention name is "composite waterproof floor and wall"
  • the method disclosed in the Chinese patent application of the cover plate is opened and chamfered on the upper surface functional layer.
  • the composite sheet in this embodiment comprises a substrate sheet and an upper surface functional layer covering the upper surface of the substrate sheet, wherein the upper surface functional layer and the substrate layer are bonded by an adhesive, wherein the substrate sheet is a PVC substrate.
  • the material layer on the upper surface is a veneer functional layer.
  • the preparation method was the same as in Example 1.
  • the sheet prepared in the step (2) is placed on a hot press for hot pressing for 10 to 20 minutes, and the hot pressing temperature is 60-80 ° C, and then the cooling set is taken out from the hot press.
  • the composite sheet prepared in this example has an unexpected increase in adhesion to the upper surface functional layer to the substrate layer relative to the composite sheet prepared in Example 1.
  • the composite floor prepared in the examples had an increase in tensile strength, shear strength and peel strength of 20% or more with respect to the composite floor prepared in Example 1.
  • the composite sheet in this embodiment comprises a substrate sheet and an upper surface functional layer covering the upper surface of the substrate sheet, wherein the upper surface functional layer and the substrate layer are bonded by an adhesive, wherein the substrate sheet is a PVC substrate.
  • the material layer on the upper surface is a veneer functional layer.
  • the PVC substrate sheet is formed from the following components by weight: PVC 100 parts, 210 parts of wood chips, 2 parts of stabilizer, 0.2 parts of stearic acid, 0.2 parts of PE wax, 1 part of chlorinated polyethylene, 0.5 part of ACR modifier, 1 part of titanium dioxide, 0.01 part of OB-1 whitening agent .
  • PVC, stabilizer, stearic acid, PE wax, chlorinated polyethylene, ACR modifier, titanium dioxide, OB-1 brightener are all common industrial raw materials.
  • the particle size of the wood chips is 0.1 ⁇ 2mm, and the wood chips of various woods can be used, preferably white oak wood chips.
  • the extrusion process step of the PVC substrate sheet of the present embodiment is: mixing the above raw materials at 40 ° C with uniform mixing; after the stirring is completed, transferring the materials to an extruder and heating to 150-160 ° C, The size of the nip is adjusted according to the thickness required for processing. After being fully plasticized by the screw, it is extruded into a single layer slab through a narrow nose. After further cooling by the three-roll calender, after a certain distance of the guide roller is further cooled, the edge can be wound and formed.
  • the thickness of the substrate sheet prepared in this embodiment can be adjusted according to actual needs. Generally, the substrate thickness of the substrate can be adjusted to 0.2 to 30 mm, and the more commonly used thickness is 1 to 20 mm.
  • the substrate hardness obtained by the present embodiment has a Shore D of about 73, a thermal curl of as low as ⁇ 0.5 mm, a change in water absorption quality of as low as ⁇ 0.5%, and a boiling resistance of 5 grades.
  • the substrate sheet prepared in this embodiment does not contain a plasticizer, which is beneficial to environmental protection and human health.
  • a plasticizer which is beneficial to environmental protection and human health.
  • a certain amount of plasticizer can be added according to actual needs, and the mass percentage of the plasticizer should not exceed 10%.
  • composition of the PVC substrate sheet of the composite sheet prepared in this example is different from that of Example 1.
  • content of other components except for PVC is lower than that of Example 1, but the hardness and heat curl of the finally prepared composite sheet are
  • the change in water absorption quality and the resistance to boiled water were similar to those in Example 1.
  • the composite sheet in this embodiment comprises a substrate sheet and an upper surface functional layer covering the upper surface of the substrate sheet, wherein the upper surface functional layer and the substrate layer are bonded by an adhesive, wherein the substrate sheet is a PVC substrate.
  • the material layer on the upper surface is a veneer functional layer.
  • the PVC substrate sheet is formed from the following components by weight: PVC 100 parts, 270 parts of wood chips, 6 parts of stabilizer, 0.8 parts of stearic acid, 0.8 parts of PE wax, 5 parts of chlorinated polyethylene, 2 parts of ACR modifier, 5 parts of titanium dioxide, 0.05 parts of OB-1 whitening agent .
  • PVC, stabilizer, stearic acid, PE wax, chlorinated polyethylene, ACR modifier, titanium dioxide, OB-1 brightener are all common industrial raw materials.
  • the particle size of the wood chips is 0.1 ⁇ 2mm, and the wood chips of various woods can be used, preferably white oak wood chips.
  • the extrusion process step of the PVC substrate sheet of the present embodiment is: mixing the above raw materials at 40 ° C with uniform mixing; after the stirring is completed, transferring the materials to an extruder and heating to 150-160 ° C, The size of the nip is adjusted according to the thickness required for processing. After being fully plasticized by the screw, it is extruded into a single layer slab through a narrow nose. After further cooling by the three-roll calender, after a certain distance of the guide roller is further cooled, the edge can be wound and formed.
  • the thickness of the substrate sheet prepared in this embodiment can be adjusted according to actual needs. Generally, the substrate thickness of the substrate can be adjusted to 0.2 to 30 mm, and the more commonly used thickness is 1 to 20 mm.
  • the substrate hardness obtained by the present embodiment has a Shore D of about 72, a thermal curl of as low as ⁇ 0.6 mm, a change in water absorption quality of as low as ⁇ 0.5%, and a boiling resistance of 5 grades.
  • the substrate sheet prepared in this embodiment does not contain a plasticizer, which is beneficial to environmental protection and human health.
  • a plasticizer which is beneficial to environmental protection and human health.
  • a certain amount of plasticizer can be added according to actual needs, and the mass percentage of the plasticizer should not exceed 10%.
  • composition of the PVC substrate sheet of the composite sheet prepared in this example is different from that of Example 1.
  • content of other components except for PVC is higher than that of Example 1, but the hardness and heat curl of the finally prepared composite sheet are
  • the change in water absorption quality and the resistance to boiled water were similar to those in Example 1.
  • the composite sheet in this embodiment comprises a substrate sheet and an upper surface functional layer covering the upper surface of the substrate sheet, wherein the upper surface functional layer and the substrate layer are bonded by an adhesive, wherein the substrate sheet is a PVC substrate.
  • the material layer on the upper surface is a veneer functional layer.
  • the PVC substrate sheet is formed from the following components by weight: PVC 100 parts, 65 parts of perlite, 175 parts of wood chips, 4 parts of stabilizer, 0.5 parts of stearic acid, 0.5 parts of PE wax, 5 parts of chlorinated polyethylene, 1 part of ACR modifier, 3 parts of titanium dioxide, OB-1 Brightener 0.03 parts.
  • PVC, perlite, stabilizer, stearic acid, PE wax, chlorinated polyethylene, ACR modifier, titanium dioxide, OB-1 brightener are all common industrial raw materials.
  • the particle size of the wood chips is 0.1 ⁇ 2mm, and the wood chips of various woods can be used, preferably white oak wood chips.
  • the extrusion process step of the PVC substrate sheet of the present embodiment is: mixing the above raw materials at 40 ° C with uniform mixing; after the stirring is completed, transferring the materials to an extruder and heating to 150-160 ° C, The size of the nip is adjusted according to the thickness required for processing. After being fully plasticized by the screw, it is extruded into a single layer slab through a narrow nose. After further cooling by the three-roll calender, after a certain distance of the guide roller is further cooled, the edge can be wound and formed.
  • the thickness of the substrate sheet prepared in this embodiment can be adjusted according to actual needs. Generally, the substrate thickness of the substrate can be adjusted to 0.2 to 30 mm, and the more commonly used thickness is 1 to 20 mm.
  • the substrate hardness obtained by the present embodiment has a Shore D of about 81, a thermal curl of as low as ⁇ 0.6 mm, a change in water absorption quality of as low as ⁇ 0.4%, and a boiling resistance of 5 grades.
  • the substrate sheet prepared in this embodiment does not contain a plasticizer, which is beneficial to environmental protection and human health.
  • a plasticizer which is beneficial to environmental protection and human health.
  • a certain amount of plasticizer can be added according to actual needs, and the mass percentage of the plasticizer should not exceed 10%.
  • composition of the PVC substrate sheet of the composite sheet prepared in this example is different from that of the embodiment 1, and a part of the perlite is added, and the hardness, heat curl, and water absorption quality of the finally prepared composite sheet are different from those of the first embodiment. Improved.

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Abstract

一种复合板材，包括基材板及覆盖于基材板的上表面的上表面功能层。该复合板材可以根据实际需求选择合适的上表面功能层，既可以节约资源，又具有更强的功能性和实用性。

Description

一种复合地板
技术领域
本发明属于建筑材料领域，特别涉及一种复合板材。
背景技术
目前，传统木地板多为实心地板，实心木地板的使用会消耗掉大量木材，致使环境遭到破坏，而且地板的成本也居高不下。因此，寻求现有实木地板的替代品是十分有必要的。
聚氯乙烯（PVC）作为应用最为广泛的通用塑料之一，长期以来被应用于建筑材料领域，例如作为板材或管材。在板材领域，常用的PVC板材包括硬质PVC和软质PVC，两者的增塑剂含量不同，从而造成两者的性质也有所不同，前者的增塑剂含量小于10%，而后者的增塑剂含量为30~70%。
增塑剂是工业上被广泛使用的高分子材料助剂，在塑料加工中添加这种物质，可以使其柔韧性增强，易于加工。增塑剂从化学结构分类来看，一般包括脂肪族二元酸酯类、苯二甲酸酯类、苯多酸酯类、苯甲酸酯类、多元醇酯类、氯化烃类、环氧类、柠檬酸酯类、聚酯类等多种。其中，最常用的增塑剂为邻苯二甲酸酯类或邻苯二甲酸盐类，例如邻苯二甲酸二（2-乙基己）酯（DEHP）、邻苯二甲酸二丁酯（DBP）等。增塑剂对人体具有一定的毒性，而且随着长期的使用会慢慢从PVC材料中逸出，对人体健康造成影响。由于硬质PVC中的增塑剂含量较少，其相对于软质PVC来说更加健康环保，可作为室内装饰板材长期使用。
硬质PVC板材还具有高阻燃、不吸水、可重复利用等特点，因此在建筑建材领域，尤其是板材领域，有着广泛的应用。但传统的硬质PVC也存在明显的缺点，例如硬度高，其作为板材，尤其是地板时，触感舒适度不足、且仍有轻微变形的可能。此外，传统的硬质PVC颜色单一，视觉效果差。这些缺点使得传统的硬质PVC无法满足人们对于舒适度和视觉效果的要求，因此只能较多的应用于低端的建材市场。另外，传统的PVC板材在加工时考虑到其美观性和实用性，往往需要在其表面涂漆，为了使得涂漆牢固地粘结在PVC板材的表面，需要在涂漆之前增加密着的环节，即先刷一层与PVC和涂漆均具有较好结合力的密着剂，这使得传统PVC板材的加工较为复杂。
发明内容
有鉴于现有技术的上述缺陷，本发明的目的在于提供一种相对健康环保、触感舒适、视觉美观、极不易变形的复合板材。本发明的复合板材还可以根据实际需求对其表面进行处理，以达到更强的功能性和实用性。
本发明所采用的技术方案为：一种复合板材，包括基材板及覆盖于所述基材板的上表面的上表面功能层。
优选地，所述基材板的组分包括石粉、玻璃粉、玻璃砂、玻璃渣或木屑，以及塑料。
优选地，在所述基材板中，增塑剂含量小于10%或不含增塑剂。
优选地，所述塑料是PVC。
优选地，所述基材板的组分按重量计包括：PVC100份，石粉、玻璃粉、玻璃砂、玻璃渣或木屑中的一种或一种以上210~270份。
优选地，所述基材板由按重量计的下列成分形成：PVC 100份，石粉、玻璃粉、玻璃砂、玻璃渣或木屑210~270份，稳定剂2~6份，硬脂酸0.2~0.8份，PE蜡0.2~0.8份，氯化聚乙烯1~5份，ACR改性剂0.5~2份，钛白粉1~5份，OB-1增白剂0.01~0.05份。
优选地，所述基材板由按重量计的下列成分形成：PVC 100份，石粉或木屑240份，稳定剂4份，硬脂酸0.5份，PE蜡0.5份，氯化聚乙烯3份，ACR改性剂1份，钛白粉3份，OB-1增白剂0.03份。
优选地，所述基材板的组分按重量计包括：PVC100份，珍珠岩50~80份，石粉或木屑210~270份。
优选地，所述基材板由按重量计的下列成分形成：PVC 100份，珍珠岩50~80份，石粉或木屑160~190份，稳定剂2~6份，硬脂酸0.2~0.8份，PE蜡0.2~0.8份，氯化聚乙烯1~5份，ACR改性剂0.5~2份，钛白粉1~5份，OB-1增白剂0.01~0.05份。
优选地，所述基材板由按重量计的下列成分形成：PVC 100份，珍珠岩65份，石粉或木屑175份，稳定剂4份，硬脂酸0.5份，PE蜡0.5份，氯化聚乙烯5份，ACR改性剂1份，钛白粉3份，OB-1增白剂0.03份。
优选地，所述上表面功能层为木皮、竹木复合板、碳酸钙板、硅酸钙板、石膏板、有机玻璃、金属板、塑料板、泡沫板中的一种。
优选地，所述金属板为镀锌板、0.1~0.5mm钢板中的一种
优选地，所述基材板的厚度为0.2~30mm，所述上表面功能层的厚度为0.1~15mm。
优选地，所述基材板的厚度为1~20mm，所述上表面功能层的厚度为0.5~5mm。
优选地，所述上表面功能层与基材层采用胶黏剂粘合，所述黏胶剂为AB胶、环氧树脂胶粘剂、酚醛树脂胶、聚氨酯胶、丙烯酸酯胶、PES聚酯胶、PA聚酰胺胶、PE聚乙烯胶、EVA乙烯醋酸乙烯共聚物胶、苯乙烯及其嵌段共聚物类热熔胶粘剂、脲醛树脂胶、压敏胶或醇酸酯胶中的一种或几种。
优选地，所述复合板材的制备方法还包括：通过冷压的方式增强所述上表面功能层与所述基材层之间的粘合。
优选地，所述冷压在常温下进行。
优选地，所述冷压的压力在8~12kg/ cm2。
优选地，所述冷压的时间为40~60min。
优选地，所述复合板材还包括覆盖在所述上表面功能层的上表面的漆膜保护层。
优选地，所述漆膜保护层通过将UV涂料滚涂或淋涂于所述上表面功能层的上表面形成。
优选地，所述漆膜保护层的厚度为0.08~0.25mm。
优选地，所述漆膜保护层的厚度为0.12~0.18mm。
优选地，所述漆膜保护层中含有粒径为20~300μm的氧化铝颗粒或金刚砂颗粒。
优选地，所述漆膜保护层中含有粒径为75~200μm的氧化铝颗粒或金刚砂颗粒。
优选地，其中所述氧化铝颗粒或金刚砂颗粒至少部分地嵌入所述UV涂料。
优选地，所述漆膜保护层的具体制备步骤包括：
1）使用滚涂机或淋涂设备在所述上表面功能层的上表面涂覆一层UV涂料，作为载粉层；
2）在未固化的UV涂料的上表面均匀铺撒一层氧化铝颗粒或金刚砂颗粒，并使用UV光进行照射，半固化所述载粉层；
3）使用滚涂机或淋涂设备在所述半固化的载粉层上再涂覆一层所述UV涂料，作为覆粉层，并使用UV光进行照射，以完全固化所述载粉层和所述覆粉层。
优选地，所述复合板材还包括覆盖于所述基材板的下表面的下表面功能层。
优选地，所述的下表面功能层为木板、木皮、竹木复合板、碳酸钙板、硅酸钙板、石膏板、有机玻璃、金属板、塑料板、泡沫板中的一种。
优选地，所述金属板为镀锌板、0.1~0.5mm钢板中的一种
优选地，所述木板或复合板与基材层采用第二胶黏剂粘合，所述下表面功能层与基材层采用胶黏剂粘合，所述黏胶剂为AB胶、环氧树脂胶粘剂、酚醛树脂胶、聚氨酯胶、丙烯酸酯胶、PES聚酯胶、PA聚酰胺胶、PE聚乙烯胶、EVA乙烯醋酸乙烯共聚物胶、苯乙烯及其嵌段共聚物类热熔胶粘剂、脲醛树脂胶、压敏胶或醇酸酯胶中的一种或几种。
优选地，所述复合板材还包括覆盖于所述下表面功能层的下表面的黏胶层。
优选地，所述的黏胶层为水性丙烯酸酯压敏胶、水性聚氨酯压敏胶、溶剂型橡胶压敏胶、溶剂型丙烯酸酯压敏胶、乳液型橡胶压敏胶、乳液型型丙烯酸酯压敏胶或UV胶中的一种。
优选地，所述UV胶由以下质量百分比的原料组成：
低聚物30-50%，活性单体40-60%，光引发剂3-10%，助剂1-10%；
其中，所述低聚物为聚氨酯丙烯酸酯、聚丁二烯丙烯酸酯、环氧丙烯酸酯、纯丙烯酸树脂、聚酯丙烯酸酯中的一种或几种；
所述活性单体是单官能团、双官能团、多官能团的丙烯酸酯中的一种或几种；
所述光引发剂为自由基光引发剂中的一种或几种。
优选地，所述UV胶由以下质量百分比的原料组成：
低聚物40%，活性单体50%，光引发剂6%，助剂5%。
优选地，所述单官能团丙烯酸酯为甲基丙烯酸异冰片酯、丙烯酸异冰片酯或2 (2-乙氧基乙氧基)乙基丙烯酸；
所述双官能团丙烯酸酯为二缩三丙二醇二丙烯酸酯、1. 6-己二醇二丙烯酸酯或三环癸烷二甲醇二丙烯酸酯；
所述多官能团丙烯酸酯活性单体为三羟甲基丙烷三丙烯酸酯、三羟甲基丙烷三丙烯酸酯、季戊四醇三丙烯酸酯、二季戊四醇六丙烯酸酯中的一种或几种。
优选地，所述助剂为附着力促进剂、消泡剂、流平剂、润湿剂、抗氧剂中的一种或几种。
优选地，所述附着力促进剂为硅烷偶联剂Y-缔水甘油醚氧丙基三甲氧基硅烷、Y-氨丙基三乙氧基硅烷、Y-甲基丙烯酰氧基丙基三甲氧基硅烷、Y-甲基丙烯酰氧基丙基三乙氧基硅烷、N-（B-氨乙基）-Y -氨丙基三甲氧基硅烷和丙烯酸酯磷酸酯2-羟基乙基甲基丙烯酸酯磷酸酯、甲基丙烯酸磷酸酯中的一种或几种；
所述消泡剂为硅酮类消泡剂；
所述流平剂为有机硅类流平剂；
所述润湿剂为改性的聚二甲基硅氧烷；
所述抗氧剂为受阻酚类抗氧剂。
优选地，所述助剂为聚乙二醇2000。
优选地，所述光引发剂是2羟基-2-甲基-1-苯基-1-丙酮、1-羟基-环己基苯甲酮、2，4，6-三甲基苯甲酰基-二苯基氧化膦、双（2，4，6-三甲基苯甲酰基）苯基氧化膦、2，4，6-三甲基二苯甲酮、4-甲基二苯甲酮、2-苯基苄-2-二甲基胺-1- (4-吗啉苄苯基)丁酮中的一种或几种。
优选地，所述基材板上或复合板材上开有锁扣，上表面功能层上开有倒角。
优选地，所述复合板材的制备方法还包括：通过热压的方式增强所述上、下表面功能层与所述基材层之间的粘合。
优选地，所述黏胶层下方还包括一层离型膜。
本发明提供的复合板材可以根据实际需求选择合适的上表面功能层，既可以节约资源，又具有更强的功能性和实用性。
具体实施方式
本发明所提供的复合板材包括基材板及覆盖于所述基材板的上表面的上表面功能层。
覆盖于基材板表面的上表面功能层可根据对板材触感、视觉效果和功能效果等的实际需求进行选择。例如，为了达到自然风格的触感和视觉效果，可选用木皮或竹木复合板等由天然材料制成的板材。为了达到硬朗而冰冷的触感和富有光泽的视觉效果，可选用不锈钢板、铝合金板、钛合金板等金属板材。为了达到柔软而温润的触感或缓冲、保温等功能效果，可选用泡沫板。为了达到轻质高强、防火隔热等功能效果，可选用碳酸钙板、硅酸钙板或石膏板。为了某种特殊的效果，还可以选用有机玻璃板。为了改善硬质PVC较硬的触感，可选用塑料，例如软质PVC板材，虽然也包含了软质PVC，但比单纯使用软质PVC板材要环保健康。可见，本发明的贴皮层位于板材的表面，提供了板材所需的触感、视觉效果和功能效果，且灵活多变，可适应于不同的需求。特别是当选用的材料较昂贵，例如选用金属板时，使用廉价的硬质PVC基材替代纯的金属板不仅能够大大降低板材的成本和重量，还能保持金属板材的触感和视觉效果。
基材板和上表面功能层之间可通过胶粘剂进行结合，胶粘剂为适用于硬质PVC的聚合物胶粘剂，例如AB胶、环氧树脂胶粘剂或脲醛树脂胶等。选择胶粘剂时，原则上应选用与基材和贴皮层都具有较强的结合力的胶粘剂。例如常用的丙烯酸、环氧或聚氨酯类AB胶具有较广泛的适用性，可用于塑料与塑料、塑料与金属、金属与金属之间的结合。聚氨酯类胶粘剂，适用于PVC、TPR、橡胶、尼龙布、ABS、人工合成皮革等PU合作材料的粘接。
除了单纯使用上述胶粘剂的结合外，申请人意外地发现，还可以另外辅以热压或冷压的方式，使得基材板与上表面功能层之间的结合更为牢固。另外，当选用的上表面功能层为某些材质时，基材板和上表面功能层之间甚至可以不通过胶粘剂来结合，而是通过共挤或热压等方式来结合。例如，当上表面功能层选用软质PVC板时，可不使用粘结剂而仅使用热压或共挤的方式来进行结合。在这种情况中，两种材料在界面处由于热熔融而部分融合在一起，其粘贴效果在条件控制得当时甚至好于使用粘结剂。
本发明的板材将上表面功能层覆盖于基材板的表面，相对于传统的PVC板材的表面加工来说，可省去密着的环节。这是因为PVC通常对表面修饰材料（例如油漆）的结合性较差，为了避免表面修饰材料的脱落，通常需要在进行表面修饰之前增加密着的环节。而本发明的板材在PVC的表面覆盖了上表面功能层，从而将表面修饰转移到上表面功能层之上，而上表面功能层的材料通常对表面修饰材料的结合性较好，无需进行密着，因而省去了传统PVC板材的密着环节。
本发明的复合板材除了包括基材板和上表面功能层之外，在基材板的下面还可包括下表面功能层及其它层，例如垫层或黏胶层，垫层贴合于基材板或下表面功能层的下表面。尤其是当本发明的板材作为地板使用时，垫层可以提供更舒适的脚感、更静音的效果和更好的地面相容性。
为了便于本发明板材的安装，基材板的边缘可具有便于板材之间连接的锁扣。锁扣可采用本领域常用的形态，例如在专利WO2015118451A1、CN102051973A、CN103932510A、CN104619936A、CN104854286A、US9193137B2中公开的各种锁扣形态。
为了进一步增强本发明板材的触感、视觉效果或功能性，可在上表面功能层的上表面进行进一步处理，例如进行刷耐磨漆处理，使得本发明的板材具有更广泛的功能性，满足用户个性化定制的需求。
下面将结合具体的实施例，更清楚地描述本发明。
实施例1
该具体实施例中的复合板材包括基材板及覆盖于基材板的上表面的上表面功能层，上表面功能层与基材层采用胶黏剂粘合，其中，基材板为PVC基材板，上表面功能层为木皮功能层。
（1）PVC基材板的制备
PVC基材板由按重量计的下列成分形成：PVC 100份，木屑240份，稳定剂4份，硬脂酸0.5份，PE蜡0.5份，氯化聚乙烯3份，ACR改性剂1份，钛白粉3份，OB-1增白剂0.03份。其中，PVC、稳定剂、硬脂酸、PE蜡、氯化聚乙烯、ACR改性剂、钛白粉、OB-1增白剂皆为常规工业原料。木屑的颗粒大小为0.1~2mm，各种木材的木屑皆可，优选白橡木木屑。
本实施例的PVC基材板的挤出工艺步骤为：将上述配比的原料在40℃下搅拌均匀混合；搅拌完成后，将物料转移至挤塑成型机中并加热至150-160℃，依据加工要求的厚度调整辊隙的大小。经过螺杆的充分塑化后通过窄逢机头挤成单层板坯。再由三辊压光机降温定型后经过一段距离的导辊的进一步冷却后即可切边收卷成型。
本实施例制得的基材板的厚度可根据实际需求调整，一般作为地板的基材板可以调整厚度为0.2~30mm，更常用的厚度为1~20mm。
本实施例制得的基材板的邵氏硬度D可达70左右，热卷曲低至±1.2mm，吸水质量变化低至±0.5%，耐水煮5级。
本实施例制得的基材板不含增塑剂，有利于环保和人体健康的需要，根据本实施例披露的内容，为了降低基材板的硬度，增加踩踏舒适感，本领域技术人员也可以根据实际需要添加一定含量的增塑剂，增塑剂的质量百分含量不宜超过10%。
（2）贴木皮功能层
木皮功能层选用白橡木皮，作为地板，木皮功能层厚度为0.1~2.0 mm皆可，更常用的是0.5~5mm。黏胶剂选用常规聚氨酯热熔胶。具体制作方法包括以下步骤：
a）对PVC基材板的上表面进行清理，对木皮功能层的下表面进行清理；
b）在步骤a中清理完成的PVC基材板的上表面均匀涂覆聚氨酯热熔胶；
c）将木皮功能层的下表面和PVC基材板的上表面贴合在一起；
d）将上述贴合在一起的PVC基材板和木皮功能层置于冷压机上冷压40~60分钟。
（3）其它处理
本领域技术人员可以根据具体实际需要对该实施例中的复合板材进行其它处理，例如，可以在PVC基材板上开锁扣（如可以参照申请号为201380055155.9，发明名称为“复合防水地板和墙盖板”的中国专利申请中披露的方法开锁扣）。也可以在上表面功能层上开倒角。
本领域技术人员还可以对木皮功能层的上表面进行进一步的修饰，例如刷漆，以满足对板材视觉或功能的需求。
该实施例所制备的复合板材采用PVC基材板贴木皮功能层的方式，既节省了木材，又可以实现与实木地板同等的效果。因木皮本身对于油漆的密着性能较好，因此无需像传统PVC板材那样对硬质PVC基材的表面进行额外的密着处理。
作为该具体实施例的变形，木皮功能层也可以采用竹木复合板。木皮功能层也可以被替换成金属板或泡沫板，PVC基材板的原料中不使用木屑。如果采用金属板，为了增加踩踏的舒适度，可以适当添加一定含量的增塑剂；如果采用泡沫板，则不需要添加增塑剂。
实施例2
该具体实施例中的复合板材包括基材板、覆盖于基材板的上表面的上表面功能层、覆盖在上表面功能层的上表面的漆膜保护层，上表面功能层与基材层采用胶黏剂粘合，漆膜保护层通过将UV涂料滚涂于上表面功能层的上表面形成。其中，基材板为PVC基材板，上表面功能层为木皮功能层，漆膜保护层的主要作用是增强耐磨性能。
（1）PVC基材板的制备
制作步骤与实施例1相同。
（2）贴木皮功能层
制作步骤与实施例1相同。
（3）涂覆漆膜保护层
漆膜保护层包括耐磨载粉层、耐磨覆粉层、氧化铝颗粒。
耐磨载粉层的原料包括：氨基丙烯酸树脂70%，助剂0.1%，稀释剂丙烯酸酯5%，填充物15%，光引发剂α-羟基酮0.01%以上数值均为重量百分比，其中助剂包括流平剂、消泡剂、密着剂、湿润剂、抑制剂。以上原料皆为工业常规原料。
耐磨覆粉层的原料包括：聚醚丙烯酸树脂60%，助剂0.4%，稀释剂聚丙烯酸酯20%，填充物19.5%和光引发剂氨基酮0.1%，其中助剂包括流平剂、消泡剂、密着剂、湿润剂、抑制剂。以上原料皆为工业常规原料。
氧化铝颗粒的平均粒径为20~300μm皆可，更优选的是75~200μm。
涂覆漆膜保护层的工艺为：
a）将环氧丙烯酸树脂于60~120℃温度范围内加热至液态，倒入分散釜中；
b）向步骤a）中得到的液态环氧丙烯酸树脂中依次加入光引发剂活性胺、稀释剂丙烯酸酯和助剂，在20~40 r/s匀速下搅拌直至均匀，得到耐磨载粉层涂料；
c）使用滚涂机将步骤b）中得到的耐磨载粉层涂料涂装至步骤2）制备的板材的木皮功能层的上表面，得到耐磨载粉层，滚涂过程中，传送带的速度设置为5-20m/min；
d）将耐磨粉氧化铝均匀撒至未干的耐磨载粉层的表面，并进一步加热以使氧化铝部分地陷于耐磨载粉层；
e）使用紫外灯对步骤d）中得到的涂层进行固化干燥，固化干燥的参数设置为：传送带的速度为5-20m/min；紫外灯距离传送带的高度为10-35cm；
f）在耐磨粉上再通过滚涂覆盖耐磨覆粉层涂料；使用紫外灯对耐磨覆粉层进行固化干燥，固化干燥的参数设置为：传送带的速度为5-20m/min；紫外灯距离传送带的高度为10-35cm。
在该实施例中，漆膜保护层的厚度可以根据需要控制在0.08~0.25mm，更优选地，控制在0.12~0.18mm。
与实施例1相比，本实施例中的耐磨层其耐磨系数增加，耐磨的效果显著增加：
按照ASTM D 4060以及GB/T 15036.1-200 标准进行测试，使用TABLE磨耗仪测试：
实施例1制备的符合地板：S-33砂布条，标准≤0.08g/100r；1000转磨穿标准；
本实施例制备的复合地板：S-33砂布条，标准≤0.08g/100r；2000转磨穿标准。
（4）其它处理
本领域技术人员可以根据具体实际需要对该实施例中的复合板材进行其它处理，例如，可以在PVC基材板上开锁扣（如可以参照申请号为201380055155.9，发明名称为“复合防水地板和墙盖板”的中国专利申请中披露的方法开锁扣），也可以在上表面功能层上开倒角。
作为该具体实施例的变形，氧化铝颗粒也可以用金刚砂颗粒替代。
实施例3
该具体实施例中的复合板材包括基材板、覆盖于基材板的上表面的上表面功能层、覆盖在上表面功能层的上表面的漆膜保护层、覆盖于基材板的下表面的下表面功能层、覆盖于下表面功能层的下表面的黏胶层，上表面功能层和下表面功能层与基材层采用胶黏剂粘合，漆膜保护层通过将UV涂料滚涂于上表面功能层的上表面形成。其中，基材板为PVC基材板，上表面功能层和下表面功能层为木皮功能层，漆膜保护层的主要作用是增强耐磨性能。
（1）PVC基材板的制备
制作步骤与实施例1相同。
（2）贴上表面木皮功能层和下表面木板功能层
制作步骤与实施例1相同。
（3）涂覆漆膜保护层
制作步骤与实施例2相同。
（4）贴黏胶层
黏胶层主要采用UV压敏胶，其具体步骤为：
a）对下表面木皮功能层的下表面进行清理，保证上胶材料表面干净干燥；
b）将UV压敏胶水涂或丝印在下表面木皮功能层的下表面，保证胶层均匀无气泡，上胶厚度0.1~1mm左右；更优选的是0.15~0.5mm左右。
c）在涂或者丝印好的胶面覆盖离型膜，然后光固化，光固化能量：1500mj/cm2，固化时间可以依环境差异自行调整。
该具体实施例中的复合板材除了提供上表面木皮功能层外，还提供了下表面木板功能层，因为下表面木板功能层也用胶黏剂粘合于PVC基材板，这样可以改善踩踏的舒适感。下表面功能层所采用的木板可以由各种木材所制，因为不为使用者所见，对木板的外观品质无要求。采用质地较软的木板可以更进一步改善踩踏的舒适感。下表面功能层所采用的木板也可以用各种复合板代替。下表面功能层也可以直接采用胶黏剂（例如UV胶），不再贴另外的功能层。
采用黏胶层的复合板材在安装时可以极大地方便施工，施工时只需要将黏胶层的下表面的离型膜撕下，然后将复合地板直接贴在地面即可。在该具体实施例中，黏胶层贴在下表面功能层的下表面。作为该具体实施例的变形，也可以不采用下表面功能层，直接将黏胶层贴在PVC基材板的下表面。
作为该具体实施例的变形，UV压敏胶也可以替换为水性压敏胶或乳剂型压敏胶。当采用水性压敏胶或乳剂型压敏胶时，制备时不需要光固化步骤。
实施例4
该具体实施例中的复合板材包括基材板及覆盖于基材板的上表面的上表面功能层，上表面功能层与基材层采用胶黏剂粘合，其中，基材板为PVC基材板，上表面功能层为硅酸钙板。
（1）PVC基材板的制备
PVC基材板由按重量计的下列成分形成：PVC 100份，石粉240份，稳定剂4份，硬脂酸0.5份，PE蜡0.5份，氯化聚乙烯3份，ACR改性剂1份，钛白粉3份，OB-1增白剂0.03份。其中，PVC、稳定剂、硬脂酸、PE蜡、氯化聚乙烯、ACR改性剂、钛白粉、OB-1增白剂皆为常规工业原料。石粉的颗粒大小为0.01~0.5mm，各种常用的工业石粉皆可，优选碳酸钙粉。
本实施例的PVC基材板的挤出工艺步骤为：将上述配比的原料在40℃下搅拌均匀混合；搅拌完成后，将物料转移至挤塑成型机中并加热至150-160℃，依据加工要求的厚度调整辊隙的大小。经过螺杆的充分塑化后通过窄逢机头挤成单层板坯。再由三辊压光机降温定型后经过一段距离的导辊的进一步冷却后即可切边收卷成型。
本实施例制得的基材板的厚度可根据实际需求调整，一般作为地板的基材板可以调整厚度为0.2~30mm，更常用的厚度为1~20mm。
本实施例制得的基材板的邵氏硬度D可达83左右，热卷曲低至±1.4mm，吸水质量变化低至±0.5%，耐水煮5级。
本实施例制得的基材板不含增塑剂，有利于环保和人体健康的需要，根据本实施例披露的内容，为了降低基材板的硬度，增加踩踏舒适感，本领域技术人员也可以根据实际需要添加一定含量的增塑剂，增塑剂的质量百分含量不宜超过10%。
（2）贴硅酸钙板
作为地板，硅酸钙板厚度为0.1~2.0 mm皆可，更常用的是0.5~5mm。黏胶剂选用AB胶。采用AB胶的具体制作方法为：
a）对PVC基材板的上表面进行清理，对硅酸钙板的下表面进行清理；
b）在步骤a中清理完成的PVC基材板的上表面均匀涂覆一层A胶或B较，在硅酸钙板的下表面对应地均匀涂覆一层B胶或A胶；
c）将硅酸钙板的下表面和PVC基材板的上表面贴合在一起。
上述步骤b也可以是先将A胶和B胶大致等体积地混合均匀，在3分钟之内将混合后的A胶和B胶均匀涂覆于PVC基材板的上表面和/或硅酸钙板的下表面，然后立即进行上述步骤C。AB胶也可以用环氧树脂胶粘剂替代。
（3）其它处理
本领域技术人员可以根据具体实际需要对该实施例中的复合板材进行其它处理，例如，可以在PVC基材板上开锁扣（如可以参照申请号为201380055155.9，发明名称为“复合防水地板和墙盖板”的中国专利申请中披露的方法开锁扣），也可以在上表面功能层上开倒角。
本领域技术人员还可以对硅酸钙板的上表面进行进一步的修饰，例如刷漆，以满足对板材视觉或功能的需求。
该实施例所制备的复合地板采用PVC基材板贴硅酸钙板的方式，既节省了石材，又可以实现与石质地板同等的效果。
作为该具体实施例的变形，硅酸钙板也可以被替换成碳酸钙板、石膏板、有机玻璃。
实施例5
该具体实施例中的复合板材包括基材板及覆盖于基材板的上表面的上表面功能层，上表面功能层与基材层采用胶黏剂粘合，其中，基材板为PVC基材板，上表面功能层为软质PVC板。
（1）PVC基材板的制备
PVC基材板由按重量计的下列成分形成：PVC 100份，稳定剂4份，硬脂酸0.5份，PE蜡0.5份，氯化聚乙烯3份，ACR改性剂1份，钛白粉3份，OB-1增白剂0.03份。其中，PVC、稳定剂、硬脂酸、PE蜡、氯化聚乙烯、ACR改性剂、钛白粉、OB-1增白剂皆为常规工业原料。
本实施例的PVC基材板的挤出工艺步骤为：将上述配比的原料在40℃下搅拌均匀混合；搅拌完成后，将物料转移至挤塑成型机中并加热至150-160℃，依据加工要求的厚度调整辊隙的大小。经过螺杆的充分塑化后通过窄逢机头挤成单层板坯。再由三辊压光机降温定型后经过一段距离的导辊的进一步冷却后即可切边收卷成型。
本实施例制得的基材板的厚度可根据实际需求调整，一般作为地板的基材板可以调整厚度为0.2~30mm，更常用的厚度为1~20mm。
本实施例制得的基材板的邵氏硬度D可达83左右，热卷曲低至±0.8mm，吸水质量变化低至±0.5%，耐水煮5级。
本实施例制得的基材板不含增塑剂，有利于环保和人体健康的需要。
（2）软质PVC板的制备
软质PVC板与PVC基材板的成分不同的是，在PVC基材板的成分的基础上添加质量百分比为5%~10%的增塑剂，作为地板，软质PVC板的厚度为0.1~2.0 mm皆可，更常用的是0.5~5mm。
（3）贴软质PVC板
制作步骤与实施例4中贴硅酸钙板的工艺相同。
可选地，该实施例中的软质PVC板也可不使用胶粘剂，而是直接将硬质PVC基材板和软质PVC板共挤形成双层结构。
（4）其它处理
本领域技术人员可以根据具体实际需要对该实施例中的复合板材进行其它处理，例如，可以在PVC基材板上开锁扣（如可以参照申请号为201380055155.9，发明名称为“复合防水地板和墙盖板”的中国专利申请中披露的方法开锁扣），在上表面功能层上开倒角。
本领域技术人员还可以对硅酸钙板的上表面进行进一步的修饰，例如刷漆，以满足对板材视觉或功能的需求。
该实施例的复合结合了硬质PVC和软质PVC各自的优点，硬质PVC为板材提供了较强的强度和较少的增塑剂含量，而软质PVC弥补了硬质PVC坚硬、触感不佳的缺点。
实施例6
该具体实施例中的复合板材包括基材板及覆盖于基材板的上表面的上表面功能层，上表面功能层与基材层采用胶黏剂粘合，其中，基材板为PVC基材板，上表面功能层为有机玻璃板。
（1）PVC基材板的制备
制备方法与实施例1相同。
（2）贴有机玻璃板
作为地板，有机玻璃板厚度为0.1~2.0 mm皆可，更常用的是0.5~5mm。黏胶剂选用丙烯酸酯胶。具体制作方法包括以下步骤：
a）对PVC基材板的上表面进行清理，对有机玻璃板的下表面进行清理；
b）在步骤a中清理完成的PVC基材板的上表面均匀涂覆丙烯酸酯胶；
c）将有机玻璃板的下表面和PVC基材板的上表面贴合在一起。
（3）其它处理
本领域技术人员可以根据具体实际需要对该实施例中的复合板材进行其它处理，例如，可以在PVC基材板上开锁扣（如可以参照申请号为201380055155.9，发明名称为“复合防水地板和墙盖板”的中国专利申请中披露的方法开锁扣），在上表面功能层上开倒角。
实施例7
该具体实施例中的复合板材包括基材板及覆盖于基材板的上表面的上表面功能层，上表面功能层与基材层采用胶黏剂粘合，其中，基材板为PVC基材板，上表面功能层为木皮功能层。
（1）PVC基材板的制备
制备方法与实施例1相同。
（2）贴木皮功能层
具体步骤与实施例1相同。
（3）热压
将步骤（2）制备好的板材置于热压机上热压10~20分钟，热压温度60-80℃，然后从热压机取出冷却定型。
申请人意外地发现，该实施例制备的复合板材相对于实施例1制备的复合板材，上表面功能层与基材层的粘合力有了意想不到的提升。参照国标：GB/T6329-1996胶粘剂对接接头拉伸强度的测定；GB/T6328-1999胶粘剂剪切冲击强度试验方法；GB/T7124-2008 胶粘剂拉伸剪切强度的测定（刚性材料对刚性材料），对实施例1制备的复合板材和本实施例制备的复合板材进行拉伸强度、剪切强度和剥离强度的测试，结果显示，本实施例制备的复合地板相对于实施例1制备的复合地板的拉伸强度、剪切强度和剥离强度具有20%以上的提升。
实施例8
该具体实施例中的复合板材包括基材板及覆盖于基材板的上表面的上表面功能层，上表面功能层与基材层采用胶黏剂粘合，其中，基材板为PVC基材板，上表面功能层为木皮功能层。
（1）PVC基材板的制备
PVC基材板由按重量计的下列成分形成：PVC 100份，木屑210份，稳定剂2份，硬脂酸0.2份，PE蜡0.2份，氯化聚乙烯1份，ACR改性剂0.5份，钛白粉1份，OB-1增白剂0.01份。其中，PVC、稳定剂、硬脂酸、PE蜡、氯化聚乙烯、ACR改性剂、钛白粉、OB-1增白剂皆为常规工业原料。木屑的颗粒大小为0.1~2mm，各种木材的木屑皆可，优选白橡木木屑。
本实施例的PVC基材板的挤出工艺步骤为：将上述配比的原料在40℃下搅拌均匀混合；搅拌完成后，将物料转移至挤塑成型机中并加热至150-160℃，依据加工要求的厚度调整辊隙的大小。经过螺杆的充分塑化后通过窄逢机头挤成单层板坯。再由三辊压光机降温定型后经过一段距离的导辊的进一步冷却后即可切边收卷成型。
本实施例制得的基材板的厚度可根据实际需求调整，一般作为地板的基材板可以调整厚度为0.2~30mm，更常用的厚度为1~20mm。
本实施例制得的基材板的邵氏硬度D可达73左右，热卷曲低至±0.5mm，吸水质量变化低至±0.5%，耐水煮5级。
本实施例制得的基材板不含增塑剂，有利于环保和人体健康的需要，根据本实施例披露的内容，为了降低基材板的硬度，增加踩踏舒适感，本领域技术人员也可以根据实际需要添加一定含量的增塑剂，增塑剂的质量百分含量不宜超过10%。
（2）贴木皮功能层
具体步骤与实施例1相同。
本实施例制备的复合板材的PVC基材板的组分与实施例1有所不同，除PVC外，其他组分的含量比实施例1低，但最终制备的复合板材的硬度、热卷曲、吸水质量变化、耐水煮的性能与实施例1相似。
实施例9
该具体实施例中的复合板材包括基材板及覆盖于基材板的上表面的上表面功能层，上表面功能层与基材层采用胶黏剂粘合，其中，基材板为PVC基材板，上表面功能层为木皮功能层。
（1）PVC基材板的制备
PVC基材板由按重量计的下列成分形成：PVC 100份，木屑270份，稳定剂6份，硬脂酸0.8份，PE蜡0.8份，氯化聚乙烯5份，ACR改性剂2份，钛白粉5份，OB-1增白剂0.05份。其中，PVC、稳定剂、硬脂酸、PE蜡、氯化聚乙烯、ACR改性剂、钛白粉、OB-1增白剂皆为常规工业原料。木屑的颗粒大小为0.1~2mm，各种木材的木屑皆可，优选白橡木木屑。
本实施例的PVC基材板的挤出工艺步骤为：将上述配比的原料在40℃下搅拌均匀混合；搅拌完成后，将物料转移至挤塑成型机中并加热至150-160℃，依据加工要求的厚度调整辊隙的大小。经过螺杆的充分塑化后通过窄逢机头挤成单层板坯。再由三辊压光机降温定型后经过一段距离的导辊的进一步冷却后即可切边收卷成型。
本实施例制得的基材板的厚度可根据实际需求调整，一般作为地板的基材板可以调整厚度为0.2~30mm，更常用的厚度为1~20mm。
本实施例制得的基材板的邵氏硬度D可达72左右，热卷曲低至±0.6mm，吸水质量变化低至±0.5%，耐水煮5级。
本实施例制得的基材板不含增塑剂，有利于环保和人体健康的需要，根据本实施例披露的内容，为了降低基材板的硬度，增加踩踏舒适感，本领域技术人员也可以根据实际需要添加一定含量的增塑剂，增塑剂的质量百分含量不宜超过10%。
（2）贴木皮功能层
具体步骤与实施例1相同。
本实施例制备的复合板材的PVC基材板的组分与实施例1有所不同，除PVC外，其他组分的含量比实施例1高，但最终制备的复合板材的硬度、热卷曲、吸水质量变化、耐水煮的性能与实施例1相似。
实施例10
该具体实施例中的复合板材包括基材板及覆盖于基材板的上表面的上表面功能层，上表面功能层与基材层采用胶黏剂粘合，其中，基材板为PVC基材板，上表面功能层为木皮功能层。
（1）PVC基材板的制备
PVC基材板由按重量计的下列成分形成：PVC 100份，珍珠岩65份，木屑175份，稳定剂4份，硬脂酸0.5份，PE蜡0.5份，氯化聚乙烯5份，ACR改性剂1份，钛白粉3份，OB-1增白剂0.03份。其中，PVC、珍珠岩、稳定剂、硬脂酸、PE蜡、氯化聚乙烯、ACR改性剂、钛白粉、OB-1增白剂皆为常规工业原料。木屑的颗粒大小为0.1~2mm，各种木材的木屑皆可，优选白橡木木屑。
本实施例的PVC基材板的挤出工艺步骤为：将上述配比的原料在40℃下搅拌均匀混合；搅拌完成后，将物料转移至挤塑成型机中并加热至150-160℃，依据加工要求的厚度调整辊隙的大小。经过螺杆的充分塑化后通过窄逢机头挤成单层板坯。再由三辊压光机降温定型后经过一段距离的导辊的进一步冷却后即可切边收卷成型。
本实施例制得的基材板的厚度可根据实际需求调整，一般作为地板的基材板可以调整厚度为0.2~30mm，更常用的厚度为1~20mm。
本实施例制得的基材板的邵氏硬度D可达81左右，热卷曲低至±0.6mm，吸水质量变化低至±0.4%，耐水煮5级。
本实施例制得的基材板不含增塑剂，有利于环保和人体健康的需要，根据本实施例披露的内容，为了降低基材板的硬度，增加踩踏舒适感，本领域技术人员也可以根据实际需要添加一定含量的增塑剂，增塑剂的质量百分含量不宜超过10%。
（2）贴木皮功能层
具体步骤与实施例1相同。
本实施例制备的复合板材的PVC基材板的组分与实施例1有所不同，添加了部分珍珠岩，最终制备的复合板材的硬度、热卷曲、吸水质量变化的性能相对于实施例1有所提升。
以上详细描述了本发明的较佳具体实施例。应当理解，本领域的普通技术无需创造性劳动就可以根据本发明的构思作出诸多修改和变化。因此，凡本技术领域中技术人员依本发明的构思在现有技术的基础上通过逻辑分析、推理或者有限的试验可以得到的技术方案，皆应在由权利要求书所确定的保护范围内。

Claims (41)

  1. 一种复合板材，其特征在于：包括基材板及覆盖于所述基材板的上表面的上表面功能层。
  2. 根据权利要求1所述的复合板材，其特征在于：所述基材板的组分包括石粉或木屑，以及塑料。
  3. 根据权利要求2所述的复合板材，其特征在于：在所述基材板中，增塑剂含量小于10%或不含增塑剂。
  4. 根据权利要求2所述的复合板材，其特征在于：所述塑料是PVC。
  5. 根据权利要求4所述的复合板材，其特征在于：所述基材板的组分按重量计包括：PVC100份，石粉或木屑210~270份。
  6. 根据权利要求5所述的复合板材，其特征在于：所述基材板由按重量计的下列成分形成：PVC 100份，石粉或木屑210~270份，稳定剂2~6份，硬脂酸0.2~0.8份，PE蜡0.2~0.8份，氯化聚乙烯1~5份，ACR改性剂0.5~2份，钛白粉1~5份，OB-1增白剂0.01~0.05份。
  7. 根据权利要求6所述的复合板材，其特征在于：所述基材板由按重量计的下列成分形成：PVC 100份，石粉或木屑240份，稳定剂4份，硬脂酸0.5份，PE蜡0.5份，氯化聚乙烯3份，ACR改性剂1份，钛白粉3份，OB-1增白剂0.03份。
  8. 根据权利要求4所述的复合板材，其特征在于：所述基材板的组分按重量计包括：PVC100份，珍珠岩50~80份，石粉或木屑210~270份。
  9. 如权利要求8所述的复合板材，其特征在于：所述基材板由按重量计的下列成分形成：PVC 100份，珍珠岩50~80份，石粉或木屑160~190份，稳定剂2~6份，硬脂酸0.2~0.8份，PE蜡0.2~0.8份，氯化聚乙烯1~5份，ACR改性剂0.5~2份，钛白粉1~5份，OB-1增白剂0.01~0.05份。
  10. 如权利要求9所述的复合板材，其特征在于：所述基材板由按重量计的下列成分形成：PVC 100份，珍珠岩65份，石粉或木屑175份，稳定剂4份，硬脂酸0.5份，PE蜡0.5份，氯化聚乙烯5份，ACR改性剂1份，钛白粉3份，OB-1增白剂0.03份。
  11. 根据权利要求1所述的复合板材，其特征在于：所述上表面功能层为木皮、竹木复合板、碳酸钙板、硅酸钙板、石膏板、有机玻璃、金属板、塑料板、泡沫板中的一种。
  12. 根据权利要求1所述的复合板材，其特征在于：所述基材板的厚度为0.2~30mm，所述上表面功能层的厚度为0.1~15mm。
  13. 根据权利要求12所述的复合板材，其特征在于：所述基材板的厚度为1~20mm，所述上表面功能层的厚度为0.5~5mm。
  14. 根据权利要求1所述的复合板材，其特征在于：所述上表面功能层与基材层采用胶黏剂粘合，所述黏胶剂为AB胶、环氧树脂胶粘剂、酚醛树脂胶、聚氨酯胶、丙烯酸酯胶、PES聚酯胶、PA聚酰胺胶、PE聚乙烯胶、EVA乙烯醋酸乙烯共聚物胶、苯乙烯及其嵌段共聚物类热熔胶粘剂、脲醛树脂胶、压敏胶或醇酸酯胶中的一种或几种。
  15. 根据权利要求14所述的复合板材，其特征在于：所述复合板材的制备方法还包括：通过冷压的方式增强所述上表面功能层与所述基材层之间的粘合。
  16. 根据权利要求15所述的复合板材，其特征在于：所述冷压在常温下进行。
  17. 根据权利要求16所述的复合板材，其特征在于：所述冷压的压力在 8~12kg/c㎡。
  18. 根据权利要求17所述的复合板材，其特征在于：所述冷压的时间为40~60min。
  19. 根据权利要求1所述的复合板材，其特征在于：所述复合板材还包括覆盖在所述上表面功能层的上表面的漆膜保护层。
  20. 根据权利要求19所述的复合板材，其特征在于：所述漆膜保护层通过将UV涂料滚涂或淋涂于所述上表面功能层的上表面形成。
  21. 根据权利要求20所述的复合板材，其特征在于：所述漆膜保护层的厚度为0.08~0.25mm。
  22. 根据权利要求21所述的复合板材，其特征在于：所述漆膜保护层的厚度为0.12~0.18mm。
  23. 根据权利要求19所述的复合板材，其特征在于：所述漆膜保护层中含有粒径为20~300μm的氧化铝颗粒或金刚砂颗粒。
  24. 根据权利要求23所述的复合板材，其特征在于：所述漆膜保护层中含有粒径为75~200μm的氧化铝颗粒或金刚砂颗粒。
  25. 如权利要求24所述的复合板材，其特征在于：其中所述氧化铝颗粒或金刚砂颗粒至少部分地嵌入所述UV涂料。
  26. 如权利要求25所述的复合板材，其特征在于：所述漆膜保护层的具体制备步骤包括：
    1）使用滚涂机或淋涂设备在所述上表面功能层的上表面涂覆一层UV涂料，作为载粉层；
    2）在未固化的UV涂料的上表面均匀铺撒一层氧化铝颗粒或金刚砂颗粒，并使用UV光进行照射，半固化所述载粉层；
    3）使用滚涂机或淋涂设备在所述半固化的载粉层上再涂覆一层所述UV涂料，作为覆粉层，并使用UV光进行照射，以完全固化所述载粉层和所述覆粉层。
  27. 根据权利要求19所述的复合板材，其特征在于：所述复合板材还包括覆盖于所述基材板的下表面的下表面功能层。
  28. 根据权利要求27所述的复合板材，其特征在于：所述的下表面功能层为木板、木皮、竹木复合板、碳酸钙板、硅酸钙板、石膏板、有机玻璃、金属板、塑料板、泡沫板中的一种。
  29. 根据权利要求28所述的复合板材，其特征在于：所述下表面功能层与基材层采用胶黏剂粘合，所述黏胶剂为AB胶、环氧树脂胶粘剂、酚醛树脂胶、聚氨酯胶、丙烯酸酯胶、PES聚酯胶、PA聚酰胺胶、PE聚乙烯胶、EVA乙烯醋酸乙烯共聚物胶、苯乙烯及其嵌段共聚物类热熔胶粘剂、脲醛树脂胶、压敏胶或醇酸酯胶中的一种或几种。
  30. 根据权利要求27所述的复合板材，其特征在于：所述复合板材还包括覆盖于所述下表面功能层的下表面的黏胶层。
  31. 根据权利要求30所述的复合地板，其特征在于：所述的黏胶层为水性丙烯酸酯压敏胶、水性聚氨酯压敏胶、溶剂型橡胶压敏胶、溶剂型丙烯酸酯压敏胶、乳液型橡胶压敏胶、乳液型型丙烯酸酯压敏胶或UV胶中的一种。
  32. 根据权利要求31所述的复合板材，其特征在于：所述UV胶由以下质量百分比的原料组成：
    低聚物30-50%，活性单体40-60%，光引发剂3-10%，助剂1-10%；
    其中，所述低聚物为聚氨酯丙烯酸酯、聚丁二烯丙烯酸酯、环氧丙烯酸酯、纯丙烯酸树脂、聚酯丙烯酸酯中的一种或几种；
    所述活性单体是单官能团、双官能团、多官能团的丙烯酸酯中的一种或几种；
    所述光引发剂为自由基光引发剂中的一种或几种。
  33. 根据权利要求32所述的复合板材，其特征在于：所述UV胶由以下质量百分比的原料组成：
    低聚物40%，活性单体50%，光引发剂6%，助剂5%。
  34. 根据权利要求32所述的复合板材，其特征在于：所述单官能团丙烯酸酯为甲基丙烯酸异冰片酯、丙烯酸异冰片酯或2 (2-乙氧基乙氧基)乙基丙烯酸；
    所述双官能团丙烯酸酯为二缩三丙二醇二丙烯酸酯、1. 6-己二醇二丙烯酸酯或三环癸烷二甲醇二丙烯酸酯；
    所述多官能团丙烯酸酯活性单体为三羟甲基丙烷三丙烯酸酯、三羟甲基丙烷三丙烯酸酯、季戊四醇三丙烯酸酯、二季戊四醇六丙烯酸酯中的一种或几种。
  35. 根据权利要求32所述的复合板材，其特征在于：所述助剂为附着力促进剂、消泡剂、流平剂、润湿剂、抗氧剂中的一种或几种。
  36. 根据权利要求35所述的复合板材，其特征在于：所述附着力促进剂为硅烷偶联剂Y-缔水甘油醚氧丙基三甲氧基硅烷、Y-氨丙基三乙氧基硅烷、Y-甲基丙烯酰氧基丙基三甲氧基硅烷、Y-甲基丙烯酰氧基丙基三乙氧基硅烷、N-（B-氨乙基）-Y -氨丙基三甲氧基硅烷和丙烯酸酯磷酸酯2-羟基乙基甲基丙烯酸酯磷酸酯、甲基丙烯酸磷酸酯中的一种或几种；
    所述消泡剂为硅酮类消泡剂；
    所述流平剂为有机硅类流平剂；
    所述润湿剂为改性的聚二甲基硅氧烷；
    所述抗氧剂为受阻酚类抗氧剂。
  37. 根据权利要求35所述的复合板材，其特征在于：所述助剂为聚乙二醇2000。
  38. 根据权利要求32所述的复合板材，其特征在于：所述光引发剂是2羟基-2-甲基-1-苯基-1-丙酮、1-羟基-环己基苯甲酮、2，4，6-三甲基苯甲酰基-二苯基氧化膦、双（2，4，6-三甲基苯甲酰基）苯基氧化膦、2，4，6-三甲基二苯甲酮、4-甲基二苯甲酮、2-苯基苄-2-二甲基胺-1- (4-吗啉苄苯基)丁酮中的一种或几种。
  39. 根据权利要求30所述的复合板材，其特征在于：所述基材板上或复合板材上开有锁扣，上表面功能层上开有倒角。
  40. 根据权利要求14所述的复合板材，其特征在于：所述复合板材的制备方法还包括：通过热压的方式增强所述上表面功能层与所述基材层之间的粘合。
  41. 根据权利要求30所述的复合板材，其特征在于：所述黏胶层下方还包括一层离型膜。
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