WO2020124342A1 - 一种防水耐磨复合地板及生产方法 - Google Patents

一种防水耐磨复合地板及生产方法 Download PDF

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Publication number
WO2020124342A1
WO2020124342A1 PCT/CN2018/121649 CN2018121649W WO2020124342A1 WO 2020124342 A1 WO2020124342 A1 WO 2020124342A1 CN 2018121649 W CN2018121649 W CN 2018121649W WO 2020124342 A1 WO2020124342 A1 WO 2020124342A1
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Prior art keywords
layer
composite
corona
pvc
waterproof
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PCT/CN2018/121649
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English (en)
French (fr)
Inventor
郑素梅
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郑素梅
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Publication date
Application filed by 郑素梅 filed Critical 郑素梅
Priority to CN201880022638.1A priority Critical patent/CN110573341B/zh
Priority to US17/253,380 priority patent/US20210309003A1/en
Priority to CA3104556A priority patent/CA3104556A1/en
Priority to PCT/CN2018/121649 priority patent/WO2020124342A1/zh
Publication of WO2020124342A1 publication Critical patent/WO2020124342A1/zh

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    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/025—Polyolefin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/51—Elastic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/554—Wear resistance
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/726—Permeability to liquids, absorption
    • B32B2307/7265—Non-permeable
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/73—Hydrophobic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/732—Dimensional properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2310/00—Treatment by energy or chemical effects
    • B32B2310/028—Treatment by energy or chemical effects using vibration, e.g. sonic or ultrasonic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2310/00—Treatment by energy or chemical effects
    • B32B2310/14—Corona, ionisation, electrical discharge, plasma treatment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2419/00—Buildings or parts thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2419/00—Buildings or parts thereof
    • B32B2419/04—Tiles for floors or walls
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F2201/00—Joining sheets or plates or panels
    • E04F2201/04—Other details of tongues or grooves
    • E04F2201/043—Other details of tongues or grooves with tongues and grooves being formed by projecting or recessed parts of the panel layers
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F2290/00—Specially adapted covering, lining or flooring elements not otherwise provided for
    • E04F2290/04—Specially adapted covering, lining or flooring elements not otherwise provided for for insulation or surface protection, e.g. against noise, impact or fire
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F2290/00—Specially adapted covering, lining or flooring elements not otherwise provided for
    • E04F2290/04—Specially adapted covering, lining or flooring elements not otherwise provided for for insulation or surface protection, e.g. against noise, impact or fire
    • E04F2290/044—Specially adapted covering, lining or flooring elements not otherwise provided for for insulation or surface protection, e.g. against noise, impact or fire against impact

Definitions

  • the invention relates to the technical field of composite flooring, in particular to a waterproof and wear-resistant composite flooring and a production method.
  • the composite floor is composed of a plurality of different material layers sequentially glued together.
  • the material layer of the composite floor includes a wear-resistant layer on the surface, a plastic layer in the middle, and a base material layer that is the bottom layer and serves as the main body layer.
  • the base material layer is selected.
  • the wood-plastic layer or stone-plastic layer, the current processing technology of composite flooring is simply to apply glue, hot press and hold pressure, specifically to press the corresponding material layer on the surface of the substrate layer in sequence, which is the first Roll the glue on the adjoining surfaces of the two adjacent material layers, and then hot press and hold the pressure to finally obtain the composite floor.
  • the middle plastic layer cannot exhaust the air that exists in the middle area. After the pressing operation, there are often various bulges in the hollow area, which seriously affects the quality and life of the composite floor.
  • the first object of the present invention is to provide a method for producing a waterproof and wear-resistant composite floor.
  • the process is simple, easy to implement, shorten the production cycle, reduce the labor and material resources required in the production process, and reduce the production cost.
  • the second object of the present invention is to provide a waterproof and wear-resistant composite floor, which has a simple structure, has very good waterproof performance and wear resistance, and the waterproof and wear-resistant composite floor will not produce bulging and is not easy Layered or deformed.
  • the technical solution adopted by the present invention is: a method for producing a waterproof and wear-resistant composite floor, including the following steps:
  • the sub-step of PVC composite layer embryo production convey the PVC wear-resistant layer, PVC pattern layer and PVC plastic layer to the hot-press equipment for hot-press lamination, and the PVC wear-resistant laminate is placed on top of the PVC pattern layer.
  • the patterns are stacked on top of the PVC plastic layer, and the PVC wear-resistant layer, PVC pattern layer and PVC plastic layer are hot-pressed and combined into an integrated composite sheet or composite film by hot-pressing equipment to obtain a PVC composite layer embryo.
  • the micro-holes with a full diameter of 0.01-0.1mm, the micro-holes of PVC composite layer embryo parts extend to the depth of PVC composite layer embryo parts of 0.01-0.1mm;
  • Sub-step of applying UV lacquer to PVC composite layer embryo parts Roll or spray UV lacquer on the upper surface of corona-treated PVC composite layer embryo parts to form a UV paint layer;
  • Sub-step of heat treatment of PVC composite layer embryo parts heat treatment of PVC composite layer embryo parts, heating PVC composite layer embryo parts first, heating temperature 80 ⁇ 120°C, heating time 1-10 minutes, then Place the PVC composite layer embryo parts in a temperature environment with a temperature of 10 ⁇ 25 °C and cool them at room temperature, then cool them rapidly for 1-10 minutes;
  • the cushion layer is transported to the corona processing equipment, and the lower surface of the cushion layer is corona treated to form a second corona microporous surface on the lower surface of the cushion layer, the second corona micro
  • the surface of the hole surface is covered with micro-holes with a diameter of 0.01-0.1mm, and the micro-holes of the second corona micro-hole surface extend to the depth of the cushion layer is 0.01-0.1mm;
  • Cutting transport the corona-treated cushion layer to the cutting equipment for cutting, so that the shape of the cushion layer matches the shape of the PVC composite layer preform, or the shape of the cushion layer and the shape of the waterproof substrate layer Match
  • Sanding the waterproof substrate layer transporting the waterproof substrate layer to the sanding equipment, and sanding the upper surface of the waterproof substrate layer to form a flat sanding surface;
  • the waterproof base material layer is transferred to the glue machine, the glue is coated on the sanded surface of the waterproof base material layer, and the first glue composite surface is formed on the sanded surface of the waterproof base material layer;
  • a composite cushion layer, the perforated cushion layer is attached to the surface of the waterproof base material layer, and the second corona microporous surface of the perforated cushion layer corresponds to the first glue composite surface compositely attached to the waterproof base material layer , Get a preliminary composite layer of waterproof base material, set aside for use;
  • Ultrasonic composite treatment of cushion layer convey the preliminary composite layer of waterproof base material to the ultrasonic press equipped with ultrasonic pressure plate, place the preliminary composite layer of waterproof base material on the ultrasonic pressure bonding platform, and control the ultrasonic pressure plate above the ultrasonic pressure bonding platform downward Move and press on the perforated cushion layer of the preliminary composite layer of the waterproof base material, energize the ultrasonic pressure plate, raise the temperature of the ultrasonic pressure plate to 80 ⁇ 120 °C, at the same time turn on the ultrasonic generator, through the installation on the back of the ultrasonic pressure plate
  • the ultrasonic frequency conversion rod transmits ultrasonic waves to the ultrasonic platen, and the ultrasonic platen transmits ultrasonic waves to the perforated cushion layer and the composite interface between the perforated cushion layer and the waterproof substrate layer to perform ultrasonic thermal compounding.
  • the ultrasonic thermal compounding process includes three Sub-steps:
  • Ultrasonic thermal composite substep After the air at the interface is evacuated, the ultrasonic pressure plate is controlled to maintain the set pressure and temperature. Under the combined action of temperature, pressure and ultrasound, the second corona micropore surface penetrates into Below the surface of the waterproof base material layer, the porous cushion layer is firmly compounded on the upper surface of the waterproof base material layer to obtain a waterproof base material composite layer;
  • the waterproof substrate composite layer is transported to the corona equipment, and the upper surface of the cushion layer above the waterproof substrate composite layer is corona treated to form a third corona microporous surface, the third The surface of the halo microporous surface is covered with micro holes with a diameter of 0.01-0.1mm, and the micro holes of the third corona microporous surface extend into the cushion layer to a depth of 0.01-0.1mm;
  • the waterproof base material composite layer is immediately transported to the glue machine, and glue is applied to the surface of the third corona microporous surface to form a second glue Compound surface, so that the glue can quickly penetrate into the micro-cavity with the third corona micro-pore surface;
  • the pre-cured PVC composite layer preform is attached to the waterproof substrate composite layer after the second glue treatment, the first corona micropores of the PVC composite layer preform The surface is compounded with the second glue composite surface of the waterproof substrate composite layer to obtain a composite plate;
  • Post-processing the post-processing of the original composite board, the post-processing includes at least one of sawing, cutting and groove processing;
  • a waterproof and wear-resistant composite floor comprising a waterproof substrate layer and a cushion layer, characterized in that it includes a prefabricated PVC composite layer prefabricated by a hot pressing process, and a PVC composite layer prefabricated component From top to bottom, including PVC wear layer, PVC pattern layer and PVC plastic layer,
  • the prefabricated PVC composite layer with surface corona treatment, the soft cushion layer with surface corona treatment and the waterproof substrate layer with sanding treatment are combined into a waterproof and wear-resistant composite floor by hot pressing process;
  • the lower surface of the prefabricated part of the PVC composite layer and the upper and lower surfaces of the cushion layer are densely covered with micro-cavities with a shrinkage cavity on the upper part and the bottom communicating with each other;
  • the upper surface of the cushion layer is hot-melt compounded with the PVC composite layer preform, and the lower surface is hot-melt compounded with the waterproof substrate layer, forming a continuous integration in the layer below the contact surface of the PVC composite layer preform and the cushion layer
  • the grid-shaped composite material bonding layer forms a continuous grid-shaped composite material bonding layer in the layer below the contact surface of the cushion layer and the waterproof substrate layer.
  • the present invention has the following advantages:
  • the process of the present invention is simple and easy to implement.
  • the production cycle of the waterproof and wear-resistant composite floor is shortened to 24 to 48 hours, the production cycle is shortened by 70%, the production energy consumption is reduced by 70 to 80%, and the production cost is greatly reduced.
  • the waterproof and wear-resistant composite floor produced according to the present invention has a simple structure and has very good waterproof performance and wear resistance.
  • the waterproof and wear-resistant composite floor will not cause bulging and is not easily layered or deformed.
  • FIG. 1 is a schematic structural diagram of a first waterproof and wear-resistant composite floor produced according to the production method of the present invention.
  • FIG. 2 is a schematic structural view of a second waterproof and wear-resistant composite floor produced according to the production method of the present invention.
  • PVC composite layer prefabricated parts 31 PVC wear layer 32, PVC pattern layer 33, PVC plastic layer.
  • a production method of waterproof and wear-resistant composite flooring includes the following steps,
  • the micro-holes of the parts extend to the depth of 0.01-0.1mm of the PVC composite layer embryo parts.
  • the micro-holes have an important role, which is the same as the subsequent corona treatment;
  • the lower surface of the PVC composite layer blank is corona treated to form a first corona microporous surface on the lower surface of the PVC composite layer blank.
  • the lower surface of the PVC composite layer preform 3 subjected to surface corona treatment has a corona surface, and the lower surface of the PVC composite layer preform 3 subjected to surface corona treatment is densely covered with a shrinkable cavity at the outer end and the bottom is Interconnected micro-cavities;
  • the upper surface of the cushion layer 2 is coated with a glue layer, so that the lower surface of the PVC composite layer preform 3 is more firmly compounded on the upper surface of the cushion layer 2;
  • Sub-step of heat treatment of PVC composite layer embryo parts heat treatment of PVC composite layer embryo parts, heating PVC composite layer embryo parts first, heating temperature 80 ⁇ 120°C, heating time 1-10 minutes, then Place the PVC composite layer embryo parts in a temperature environment with a temperature of 10 ⁇ 25 °C and cool them at room temperature, then cool them rapidly, and eliminate the internal stress existing in the PVC composite layer embryo parts through heat treatment, so that the PVC composite layer embryo parts The size is more stable, avoiding warpage or deformation during subsequent processing.
  • the PVC composite layer embryo parts are conveyed through a conveyor belt, so that the PVC composite layer embryo parts are sequentially passed through a tunnel oven and a normal temperature cooling water tank, and the PVC composite layer embryo parts conveyed from the tunnel oven are conveyed via
  • the belt conveyor immediately enters the normal temperature cooling water tank, and the rapid cooling is 1-10 minutes.
  • the rapid cooling time is controlled at 3-5 minutes to remove internal stress and prevent warping.
  • the temperature in the tunnel oven is controlled at 80-120°C, and the time for the PVC composite layer embryo parts to pass through the tunnel oven is controlled to be 1-10 minutes, that is, the PVC composite layer embryo parts pass through the oven Bake for 1-10 minutes; preferably, control the baking time to 3-7 minutes.
  • the temperature of the cooling water in the normal-temperature cooling water tank is controlled at 10-25°C
  • the temperature of the cooling water in the preferred normal-temperature cooling water tank is controlled at 20°C
  • the PVC composite layer blanks are transported through the conveyor belt.
  • the PVC composite layer embryo parts are partially or fully immersed in cooling water, and the time for immersing the PVC composite layer embryo parts in the cooling water is controlled to 1-10 minutes, that is, the PVC composite layer embryo parts are water-cooled After cooling for 1-10 minutes, the temperature of the PVC composite layer embryo parts is rapidly reduced to normal temperature through water cooling.
  • the PVC composite layer embryo parts are quickly dried, in particular, the PVC composite layer embryo parts are blown by a fan to achieve rapid drying and removal of PVC Water on the surface of the composite layer embryo.
  • the cushion layer 2 is transported to the corona processing equipment, and the lower surface of the cushion layer 2 is corona treated to form a second corona microporous surface on the lower surface of the cushion layer 2, the second The surface of the corona microporous surface is covered with micropores with a diameter of 0.01-0.1mm, and the micropores of the second corona microporous surface extend to the depth of the cushion layer 2 is 0.01-0.1mm;
  • the present invention is to install a corona platform on the corona device, a cross arm capable of moving back and forth along the corona platform is installed above the corona device, the cross arm crosses the conveying platform laterally, and at least one row is installed on the cross arm Corona unit, the first row of corona units are closely arranged with multiple corona nozzles, and the bottom surface of each corona nozzle is provided with densely arranged fiber bundles;
  • each corona nozzle In the process of corona, the distance between the bottom surface of each corona nozzle and the cushion layer 2 placed on the corona platform is controlled at 0.5-5cm, and the cross arm is controlled to move along the conveying table, so that each corona nozzle is removed from the corona platform Move one side to the other;
  • corona process high-frequency AC voltage is supplied to the corona unit and the bottom surface of each corona nozzle is continuously sprayed toward the corona platform.
  • the corona emitted by the corona nozzle penetrates the surface of the cushion layer 2 so that Dense micro holes are formed on the surface of the cushion layer 2 to achieve corona treatment on the upper surface of the cushion layer 2.
  • a metal pallet is fixed as a corona platform in the corona device, and the metal pallet is electrically connected to the DC positive electrode, and the surface voltage of the metal pallet is controlled at 0.5-48V;
  • An ultrasonic frequency conversion rod is fixed on the upper part of each corona unit, each corona nozzle is set as an ultrasonic directional emission head, and ultrasonic waves are provided to each ultrasonic frequency conversion rod through an ultrasonic generator to realize the transmission of ultrasonic waves to each corona unit
  • the first ultrasonic wave is directed toward the metal pallet through each corona nozzle, and the corona emitted by each corona nozzle overlaps the first ultrasonic wave emitted by the corona nozzle;
  • the first ultrasonic waves are reflected by the metal pallet, so that the reflected first ultrasonic waves are collected in the cushion layer 2 and a cavitation effect is generated in the cushion layer 2, and the cavitation effect breaks the side walls of each cavity into powder.
  • the present invention retains the powder of the cushion layer 2 formed by cavitation and crushing of its side walls in each cavity.
  • the glue penetrates into the corresponding cavity respectively, and the glue and the powder of the cushion layer 2 penetrate into the fiber gaps below the surface of the corresponding waterproof base material layer 1, respectively.
  • a composite adhesive layer 21 of a mesh shape in a continuous shape is formed in the layer below the surface of the cushion layer 2 and the layer below the surface of the waterproof base material layer 1, a composite adhesive layer 21 of a mesh shape in a continuous shape is formed.
  • the first ultrasonic wave reflected back through the metal pallet and the first ultrasonic wave and the corona emitted in the forward direction form an impact interface on the upper surface of the cushion layer 2, Furthermore, the generation area of cavitation effect is concentrated in the layer below the upper surface of the cushion layer 2, so that dense micropores are generated in the layer 0.01 to 0.1 mm below the upper surface of the cushion layer;
  • Each micro-cavity formed on the upper surface of the cushion layer 2 has a cavity and a contraction-type cavity, the cavity and the contraction-type cavity are mainly generated by corona breakdown, and the first ultrasonic wave creates voids in the cavity Chemical expansion effect to expand the volume of the cavity, and in the process of expanding the cavity, the size of the contraction type cavity remains unchanged.
  • the cavitation effect and corona break down the partial side walls of each micro-cavity, forming at least one micro-connecting through hole in the side wall of each cavity, so that the cavity of each micro-cavity is locally connected, and the upper part of the micro-cavity
  • the contraction-type hole still retains the complete side wall to separate the micro-holes separately;
  • the cavities of the adjacent through-holes 22 communicate with the through-holes 22, so that the cavity of each micro-hole on the surface of the cushion layer 2 respectively communicates with the corresponding through-hole 22 through the corresponding micro-connected through-holes to form a micro-exhaust gap, A three-dimensional exhaust network formed by interconnecting micro holes and through holes 22.
  • the through hole 22 Through the through hole 22, the air in the cushion layer 2 and its interface is quickly exhausted to avoid trapping air in the interface or the adjacent layer, thereby effectively avoiding the bulging of the waterproof and wear-resistant composite floor.
  • the diameter or width of the through hole 22 is 2-20 mm; preferably, the diameter or width of the through hole 22 is 5-10 mm.
  • the cushion layer 2 is sent to the punching equipment for punching, at least the central region of the cushion layer 2 is covered with a plurality of through holes 22, and each through hole 22 penetrates the cushion layer 2 up and down respectively to obtain a hole Cushion layer.
  • the cushion layer 2 is selected from EVA sheet, EVA film, IXPE sheet, IXPE film, IXPP sheet, IXPP film, PP sheet, PP film, PVC sheet or PVC film.
  • the cushion layer 2 is preferably an EVA sheet material or an EVA film material, and the middle part of the cushion layer 2 is covered with through holes 22 by punching.
  • Sanding the waterproof base material layer transporting the waterproof base material layer 1 to the sanding equipment, and sanding the upper surface of the waterproof base material layer 1 to form a flat sanding surface.
  • the dust on the surface of the sanding surface of the waterproof substrate layer is blown off by an air gun, or the dust on the surface of the sanding surface of the waterproof substrate layer is swept or absorbed by a brush, or the waterproof base is removed by a vacuum suction device
  • the dust on the sanding surface of the wood layer to avoid the dust flying around.
  • a layer of silane coupling agent diluent is roller-coated, roller-coated or sprayed on the sanding surface.
  • the silane coupling agent and water are diluted in proportion to obtain the silane coupling agent diluent.
  • the silane coupling agent is in the silane coupling agent diluent
  • the weight percentage in is 1-5%.
  • the drying step the sanded surface after the dust removal step is dried, the drying temperature is controlled at 80-100°C, and the drying time is controlled at 5-15 minutes.
  • the water in the silane coupling agent dilution liquid coated on the sanding surface is removed, and a thin silane coupling agent adhesive layer composed of the silane coupling agent is formed on the surface of the sanding surface.
  • the silane coupling agent adhesive layer penetrates below the surface of the sanding surface, and the silane coupling agent adhesive layer improves the composite firmness between the waterproof base material layer and the perforated cushion layer.
  • the technical solution with an adhesive layer of a silane coupling agent can increase the compounding firmness by 2-4 times.
  • the waterproof base material layer 1 is transported to the glue machine, and the glue is applied to the sanded surface of the waterproof base material layer 1, and the first glue composite surface is formed on the sanded surface of the waterproof base material layer 1;
  • the perforated cushion layer is attached to the surface of the waterproof substrate layer 1, and the second corona microporous surface of the perforated cushion layer corresponds to the first glue compounded and attached to the waterproof substrate layer 1 Composite surface, to obtain a preliminary composite layer of waterproof substrate, set aside for use;
  • Ultrasonic composite treatment of cushion layer convey the preliminary composite layer of waterproof base material to the ultrasonic press equipped with ultrasonic pressure plate, place the preliminary composite layer of waterproof base material on the ultrasonic pressure bonding platform, and control the ultrasonic pressure plate above the ultrasonic pressure bonding platform downward Move and press on the perforated cushion layer of the preliminary composite layer of the waterproof base material, energize the ultrasonic pressure plate, raise the temperature of the ultrasonic pressure plate to 80 ⁇ 120 °C, at the same time turn on the ultrasonic generator, through the installation on the back of the ultrasonic pressure plate
  • the ultrasonic frequency conversion rod transmits ultrasonic waves to the ultrasonic platen, and the ultrasonic platen transmits ultrasonic waves to the perforated cushion layer and the composite interface between the perforated cushion layer and the waterproof substrate layer 1 to perform ultrasonic thermal compounding.
  • the ultrasonic thermal compounding process includes Three substeps:
  • the pressure of the ultrasonic pressure plate on the perforated cushion layer is controlled at 0.5-0.8Mpa.
  • the ultrasonic waves transmitted into the glue produce mechanical effects and warming effects to enhance the water molecules and high molecular compounds in the glue.
  • the molecular movement increases the temperature of the glue while softening the glue, improving the fluidity of the glue, and transmitting the ultrasound to the glue to produce a physical and chemical effect at the same time, which produces a dispersive and thixotropic effect on the glue.
  • the permeability of the glue and the thixotropic effect make the glue moisture into small particles with a size of 0.01-0.1mm, so that the glue can quickly penetrate into the micro-holes of the second corona micro-pore surface and the surface of the waterproof substrate layer 1
  • a layer of powder, glue, fibers in the waterproof substrate layer 1 and fillers present in the waterproof substrate layer 1 interpenetrate in the layer below the surface of the waterproof substrate layer 1
  • the composite material bonding layer 21 formed and connected into one body;
  • the waterproof base material layer 1 is selected from waterproof composite plates.
  • the waterproof composite plates include at least one of wood-plastic plates, stone-plastic plates, plastic plates, and waterproof composite wooden boards.
  • the waterproof composite plate may be a plate with only a single layer structure, or a composite plate with at least two layer structures.
  • the water-repellent base material layer 1 is selected from wood-plastic plates, stone-plastic plates or waterproof composite wood plates.
  • the water-repellent substrate layer 1 can also be a plastic plate.
  • Corona treatment is performed on the upper surface of the plastic plate before the ultrasonic composite treatment of the cushion layer 2 is carried out, so that the upper surface of the plastic plate is covered with micro holes. Halo treatment is the same.
  • the pressure of the ultrasonic platen is gradually increased, and the pressure is controlled at 0.5-2 MPa.
  • the air with the perforated cushion layer attached to the side of the waterproof substrate layer 1 passes through the micro-cavities and the through-holes 22 respectively Discharge to avoid bulging between the perforated cushion layer and the waterproof substrate layer 1;
  • Ultrasonic thermal composite sub-step After the air at the interface is evacuated, the ultrasonic pressure plate is controlled to maintain the set pressure and temperature. Under the combined action of temperature, pressure and ultrasound, the second corona microporous surface penetrates to waterproof Below the surface of the base material layer 1, the porous cushion layer is firmly compounded on the upper surface of the waterproof base material layer 1 to obtain a waterproof base material composite layer;
  • the powder, glue and the filler existing in the water-repellent base layer 1 are transformed into a slightly melted state to form a composite mixed layer. Then, the mixed layer of the composite material is cured while holding the pressure, and finally a composite material bonding layer 21 is formed, so that the perforated cushion layer is firmly compounded on the upper surface of the waterproof base material layer 1 to obtain a waterproof base material composite layer.
  • Secondary corona treatment transporting the waterproof substrate composite layer to the corona equipment used in the primary corona treatment, and corona treatment the upper surface of the cushion layer 2 above the waterproof substrate composite layer to form a third Corona microporous surface, the surface of the third corona microporous surface is covered with micro holes with a diameter of 0.01-0.1mm, the micro holes of the third corona microporous surface extend into the cushion layer 2 to a depth of 0.01-0.1 mm;
  • the process of secondary corona treatment is the same as the process of primary corona treatment. The difference is that the corona object is different.
  • the waterproof base material composite layer is immediately transported to the glue machine, and glue is applied to the surface of the third corona microporous surface to form a second glue Compound surface so that the glue can quickly penetrate into the micro-cavities with the third corona micro-porous surface.
  • the PVC composite layer preform 3 after curing is attached to the waterproof substrate composite layer after secondary glue processing, the first corona of the PVC composite layer preform 3 immediately after the second adhesive treatment is completed
  • the microporous surface is composited with the second glue composite surface of the waterproof substrate composite layer to obtain a composite plate;
  • the cold press is provided with an ultrasonic cold pressing platform, an ultrasonic cold pressing plate is installed above the ultrasonic cold pressing platform, the composite plate is placed on the ultrasonic cold pressing platform, and the ultrasonic cold pressing plate is controlled to move downward and be pressed against the back of the composite plate.
  • Control the pressure of the ultrasonic cold platen at 1-10Mpa, and simultaneously turn on the ultrasonic generator.
  • the ultrasonic wave is transmitted to the ultrasonic cold platen through the ultrasonic frequency conversion rod installed on the upper part of the ultrasonic cold platen.
  • Ultrasonic waves are transmitted to the composite board to perform ultrasonic cold-press lamination, so that the air remaining inside the perforated cushion layer and the upper and lower sides are discharged to the outside of the composite board through the through holes 22 and micro holes.
  • the present invention is to first make PVC composite layer prefabricated parts, then perform corona treatment and punching treatment on the soft cushion layer, and finally composite the PVC composite layer prefabricated member, soft cushion layer and waterproof base material layer into a whole at one time.
  • the waterproof and wear-resistant composite floor includes a PVC composite layer prefabricated part 3 on the upper layer, a perforated cushion layer on the middle layer and a waterproof base material composite layer on the lower layer, and a PVC composite layer prefabricated part 3, perforated cushion layer and waterproof
  • the composite layer of substrate is integrated into one.
  • Post-processing the post-processing of the original composite plate, the post-processing includes at least one of sawing, cutting and groove processing;
  • the finished waterproof and wear-resistant composite floor includes a prefabricated PVC composite layer 3 in the upper layer, a soft cushion layer with holes in the middle layer and a waterproof base in the lower layer Wood composite layer, and PVC composite layer prefabricated part 3, perforated cushion layer and waterproof base material composite layer are integrated into one.
  • the process of the invention is simple and easy to implement.
  • the production cycle of the waterproof and wear-resistant composite floor is shortened to 24 to 48 hours, the production cycle is shortened by 70%, the production energy consumption is reduced by 70 to 80%, and the production cost is greatly reduced.
  • the waterproof and wear-resistant composite floor produced according to the present invention has a simple structure and has very good waterproof performance and wear resistance.
  • the waterproof and wear-resistant composite floor will not produce bulging and is not easy to be layered or deformed.
  • a waterproof and wear-resistant composite floor as shown in FIG. 1, includes a waterproof base material layer 1, a cushion layer 2 and a pre-fabricated PVC composite layer preform 3 compounded by a hot pressing process. From top to bottom, it includes a PVC wear layer 31, a PVC pattern layer 32 and a PVC plastic layer 33 in this order.
  • FIG. 1 is a schematic structural diagram of a first waterproof and wear-resistant composite floor produced according to the production method of the present invention.
  • the PVC composite layer preform 3 is a sheet or a film
  • the PVC plastic layer 33 is selected from a PVC sheet or a PVC film.
  • PVC composite layer prefabricated part 3 is a prefabricated part with extremely thin thickness, which has very good waterproof performance and wear resistance.
  • the design of PVC composite layer prefabricated part 3 can reduce the multiple surfaces required for the production of waterproof and wear-resistant composite flooring The compounding process reduces its production time (production cycle) by half, and correspondingly, it can reduce the production cost of waterproof and wear-resistant composite flooring by half.
  • the total thickness of the PVC composite layer preform 3 is 0.5-2.5 mm, preferably, the total thickness of the PVC composite layer preform 3 is 0.5-1.2 mm.
  • the thickness of the PVC plastic layer 33 is controlled at 0.6-1.5 mm, preferably, the thickness of the PVC plastic layer 33 is controlled at 0.6-1.2 mm.
  • the cushion layer 2 is made of an elastic plastic layer, for example, the cushion layer 2 is made of EVA sheet, EVA film, IXPE sheet, IXPE film, IXPP sheet, IXPP film, PP sheet, PP film, PVC Sheet or PVC film.
  • the cushion layer 2 is made of EVA sheet or EVA film.
  • the thickness of the cushion layer 2 is 0.5-2.5mm.
  • the thickness of the cushion layer 2 is controlled at 0.8-1.2mm, which can reduce The total thickness of the waterproof and wear-resistant composite floor to reduce its cost, while making the waterproof and wear-resistant composite floor and I have a better balance.
  • the lower surface of the PVC composite layer preform 3 subjected to surface corona treatment has a corona surface
  • the lower surface of the PVC composite layer preform 3 subjected to surface corona treatment is densely covered with a shrinkable cavity
  • the bottom is interconnected micro holes.
  • the upper and lower surfaces of the cushion layer 2 subjected to the surface corona treatment respectively have a corona surface.
  • the upper and lower surfaces of the cushion layer 2 subjected to the surface corona treatment are densely covered with outer ends to form a contraction type cavity, At the bottom are interconnected micro holes.
  • the diameter of the micro-holes is 0.01-0.1mm
  • the depth of the micro-holes is 0.01-0.1mm.
  • the thickness of the waterproof base material layer 1 is 3-15 mm.
  • the thickness of the waterproof base material layer 1 is controlled at 4-8 mm to serve as the main body layer of the floor, and a groove tenon 11 can be provided on the side surface thereof.
  • the waterproof base material layer 1 is selected from waterproof composite plates.
  • the waterproof composite plates include at least one of wood-plastic plates, stone-plastic plates, plastic plates, and waterproof composite wooden boards.
  • the waterproof base material layer 1 is a waterproof composite wood board or a waterproof composite fiber board.
  • the upper surface of the waterproof base material layer 1 subjected to the sanding treatment has a sanding surface.
  • a silane coupling agent diluent is coated on the surface of the sanding surface and dried to form a silane coupling agent adhesive layer on the surface of the sanding surface.
  • the lower surface of the cushion layer 2 is compounded to the upper surface of the waterproof substrate layer 1 by an ultrasonic thermal compound process, and the lower surface of the PVC composite layer preform 3 is compounded to the upper surface of the cushion layer 2 by a cold pressing process.
  • a composite adhesive layer 21 in the form of a mesh is formed into an integrated body, and the upper and lower sides of the composite material adhesive layer 21 extend to the composite cushion
  • the layer 2 and the waterproof base material layer 1 have a physical interlocking connection on the basis of the surface bonding compound, which can more firmly compound the cushion layer 2 and the waterproof base material layer 1, the cushion layer 2 and the waterproof base material layer 1 It is not easy to delaminate or deform.
  • a composite adhesive layer 21 in a grid-like shape is formed; the upper and lower surfaces of the composite adhesive layer 21 extend to PVC respectively
  • the composite layer preform 3 and the cushion layer 2 have a physical interlocking connection on the basis of the surface bonding compound, which can more firmly compound the PVC composite layer preform 3 and the cushion layer 2, the PVC composite layer preform 3 and The cushion layer 2 is not easy to delaminate.
  • the middle region of the cushion layer 2 is covered with a plurality of through holes 22 that vertically penetrate the software layer.
  • the diameter or width of the through hole 22 is 2-20 mm; preferably, the diameter or width of the through hole 22 is 5-10 mm.
  • a groove and tenon 11 is provided on the side of the waterproof and wear-resistant composite floor, and the groove and tenon 11 is only opened on the side of the waterproof base material layer 1.
  • the through hole 22 is provided with an area or position where the cushion layer 2 does not have the slot tenon 11, and the through hole 22 is away from the slot tenon 11.
  • a waterproof and wear-resistant composite floor as shown in FIG. 2, includes a waterproof base material layer 1, a cushion layer 2 and a pre-fabricated PVC composite layer preform 3 compounded by a hot pressing process.
  • the PVC composite layer preform 3 is made from From top to bottom, it includes a PVC wear layer 31, a PVC pattern layer 32 and a PVC plastic layer 33 in this order.
  • FIG. 2 is a schematic structural diagram of a second waterproof and wear-resistant composite floor produced according to the production method of the present invention.
  • the upper surface and the lower surface of the cushion layer 2 subjected to the surface corona treatment are densely covered with a shrinkable cavity at the outer end, and at the bottom are interconnected micro-cavities.
  • the upper surface of the waterproof base material layer 1 is coated with a glue layer, so that the lower surface of the cushion layer 2 is more firmly compounded on the upper surface of the waterproof base material layer 1.
  • a composite adhesive layer 21 in the form of a mesh is formed into an integrated body, and the upper and lower sides of the composite material adhesive layer 21 extend to the composite cushion
  • the layer 2 and the waterproof base material layer 1 have a physical interlocking connection on the basis of the surface bonding compound, which can more firmly compound the cushion layer 2 and the waterproof base material layer 1, the cushion layer 2 and the waterproof base material layer 1 It is not easy to delaminate or deform.
  • the upper surface of the PVC composite layer preform 3 is coated with a UV paint layer 34.
  • the UV paint layer 34 not only makes the PVC composite layer preform more decorative, but also has better wear resistance.
  • the lower surface of the PVC composite layer preform 3 subjected to surface corona treatment has a corona surface, and the lower surface of the PVC composite layer preform 3 subjected to surface corona treatment is densely covered with a shrinkable cavity at the outer end and the bottom is Interconnected miniature holes.
  • the upper surface of the cushion layer 2 is coated with a glue layer, so that the lower surface of the PVC composite layer preform 3 is more firmly compounded on the upper surface of the cushion layer 2.
  • a composite adhesive layer 21 in a grid-like shape is formed; the upper and lower surfaces of the composite adhesive layer 21 extend to PVC respectively
  • the composite layer preform 3 and the cushion layer 2 have a physical interlocking connection on the basis of the surface bonding compound, which can more firmly compound the PVC composite layer preform 3 and the cushion layer 2, the PVC composite layer preform 3 and The cushion layer 2 is not easy to delaminate.
  • the middle region of the cushion layer 2 is covered with a plurality of through holes 22 that vertically penetrate the software layer. During the compounding process, the air in the cushion layer 2 and its interface is quickly removed through the through holes 22 to avoid trapping air in the interface or adjacent layers, thereby effectively avoiding the bulging of the waterproof and wear-resistant composite floor.
  • a groove and tenon 11 is provided on the side of the waterproof and wear-resistant composite floor, and the groove and tenon 11 is only opened on the side of the waterproof base material layer 1.
  • the through hole 22 is provided with an area or position where the cushion layer 2 does not have the slot tenon 11, and the through hole 22 is away from the slot tenon 11.
  • the bottom surface of the waterproof base material layer 1 is compounded with an elastic layer 4, the elastic layer 4 is made of cork material composite layer, IXPE or EVA, the thickness of the elastic layer 4 is 1-5mm, preferably, the thickness of the elastic layer 4 is controlled at 1-2mm In order to make the composite floor have better balance and cushioning, improve the comfort of the composite floor, the elastic layer 4 also makes the waterproof and wear-resistant composite floor have better sound absorption performance, making it have a silent effect.

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Abstract

一种防水耐磨复合地板的生产方法，先制作PVC复合层预制件（3），再对软垫层（2）进行电晕处理和冲孔处理，最后将PVC复合层预制件（3）、软垫层（2）和防水基材层（1）一次性复合成一体，工艺简单，易于实施，缩短生产周期，减少生产过程所需的人力物力，降低生产成本，且生产得到的防水耐磨复合地板，不但结构简单，而且具有非常好的防水性能和耐磨性能，并且防水耐磨复合地板不会产生鼓包，也不易分层或变形。

Description

一种防水耐磨复合地板及生产方法 技术领域
本发明涉及复合地板技术领域，尤其是涉及一种防水耐磨复合地板及生产方法。
背景技术
复合地板是由多个不同的材料层依次通过胶水粘贴复合而成，复合地板的材料层包括表面的耐磨层、中间的塑料层和位于底层并作为主体层的基材层，基材层选用木塑层或石塑层，目前的复合地板的加工工艺仅是简单地涂胶、热压和保压，具体是在基材层的表面顺次往上压贴相应的材料层，其是先在相邻的两个材料层的相贴面滚涂胶水，再进行热压和保压，最终得到复合地板。
但目前仍存以下缺点需要改进：
第一，传统的生产工艺步骤较多，需要多次热压及长时间的保压加工，且每次热压后的保压加工均需要保压12至24小时，传统的生产工艺所需的能耗较大，生产周期较长，生效效率较低，生产成本较高。
第二，在热压过程中，中间的塑料层无法排出存在于中部区域的空气，在完成压贴作业后，中空区域经常存在各种鼓包，严重影响复合地板的质量和寿命。
第三，由于不同材料之间的材料特征不同，其热胀冷缩系数也不相同，生产过程中不同的材料层存在不同程度的内应力，且以胶水作为粘结剂，复合地板的各个材料层之间还是容易出现分层，在复合地板投入使用一段时间后，复合地板的四周容易产生翘曲，其防水性能也非常差。
发明内容
针对现有技术存在的不足，本发明的第一目的是提供一种防水耐磨复合地板的生产方法，工艺简单，易于实施，缩短生产周期，减少生产过程所需的人力物力，降低生产成本。
针对现有技术存在的不足，本发明的第二目的是提供一种防水耐磨复合地板，结构简单，具有非常好的防水性能和耐磨性能，防水耐磨复合地板不会产生鼓包，也不易分层或变形。
为了实现上述目的，本发明所采用的技术方案是：一种防水耐磨复合地板的生产方法，包括以下步骤：
制作PVC复合层预制件，包括以下子步骤，
a)、PVC复合层胚制件复合子步骤，将PVC耐磨层、PVC图案层和PVC塑料层一同输送至热压设备热压复合，且PVC耐磨层叠置于PVC图案层的上方，PVC图案层叠置于于PVC塑料层的上方，通过热压设备将PVC耐磨层、PVC图案层和PVC塑料层热压复合成一体式的复合片材或复合膜材，从而得到PVC复合层胚制件；
b)、PVC复合层胚制件电晕子步骤，PVC复合层胚制件电晕处理，将PVC复合层胚制件输送至电晕加工设备，对PVC复合层胚制件的上表面和/或下表面进行电晕处理，以在PVC复合层胚制件的上表面和/或下表面形成一第一电晕微孔面，使PVC复合层胚制件的上表面和/或下表面布满直径为0.01-0.1mm的微型孔穴，PVC复合层胚制件的微型孔穴延伸到PVC复合层胚制件的深度为0.01-0.1mm；
c)、PVC复合层胚制件涂UV漆子步骤，在经过电晕处理的PVC复合层胚制件的上表面辊涂或喷涂UV漆，以形成一UV漆层；
d)、PVC复合层胚制件热处理子步骤，对PVC复合层胚制件进行热处理，先对PVC复合层胚制件进行加热，加热温度80～120℃，加热时间为1-10分钟，再将PVC复合层胚制件置于温度为10～25℃的温度环境中经过常温冷却，将其急速冷却1-10分钟；
e)、PVC复合层胚制件养生处理子步骤，将经过热处理的PVC复合层胚制件放置或堆垛于养生仓中，至少养生24小时，得到PVC复合层预制件，放置一边备用；
一次电晕处理，将软垫层输送至电晕加工设备，对软垫层的下表面进行电晕处理，以在软垫层的下表面形成第二电晕微孔面，第二电晕微孔面的表面布满直径为0.01-0.1mm的微型孔穴，第二电晕微孔面的微型孔穴延伸到软垫层的深度为0.01-0.1mm；
裁切，将经过电晕处理的软垫层输送至裁切设备进行裁切，使软垫层形状与PVC复合层预制件的形状相匹配，或者使软垫层形状与防水基材层的形状相匹配；
防水基材层砂光处理，将防水基材层输送至砂光设备，对防水基材层的上表面进行砂光处理，以形成一平整的砂光面；
过胶处理，将防水基材层输送至过胶机，在防水基材层的砂光面涂布胶水，在防水基材层的砂光面之上形成第一胶水复合面；
复合软垫层，将带孔软垫层贴附在防水基材层表面，且带孔软垫层的第二电晕微孔面对应复合贴附于防水基材层的第一胶水复合面，得到防水基材初步复合层，放置一边备用；
软垫层超声复合处理，将防水基材初步复合层输送到安装有超声压板的超声波压机，将防水基材初步复合层置于超声压贴平台，控制超声压贴平台 上方的超声压板向下移动并压贴于防水基材初步复合层的带孔软垫层之上，对超声压板通电，将超声压板的温度提升至80～120℃，同时开启超声发生器，通过安装在超声压板背部的超声变频杆将超声波传导至超声压板，超声压板再将超声波传导至带孔软垫层以及带孔软垫层与防水基材层之间的复合界面，进行超声热复合，超声热复合过程包括三个子步骤：
a)、胶水渗透子步骤，控制超声压板轻压带孔软垫层，在温度和超声波共同作用下，胶水分别快速渗透进入带孔软垫层和防水基材层，
b)、气体排空子步骤，在完成胶水渗透之后，逐渐增加超声压板的压力，在压力和超声波共同作用下，将带孔软垫层与防水基材层的相接界面的空气分别通过微型孔排挤出去，
c)、超声热复合子步骤，在排空相接界面的空气之后，控制超声压板保持设定的压力和温度，在温度、压力和超声波共同作用下，使第二电晕微孔面渗透到防水基材层的表面以下，使带孔软垫层牢固复合在防水基材层的上表面，得到防水基材复合层；
二次电晕处理，将防水基材复合层输送至电晕设备，对防水基材复合层上方的软垫层的上表面进行电晕处理，以形成第三电晕微孔面，第三电晕微孔面的表面布满直径为0.01-0.1mm的微型孔穴，第三电晕微孔面的微型孔穴伸入到软垫层的深度为0.01-0.1mm；
二次过胶处理，在防水基材复合层完成二次电晕处理后立即将防水基材复合层输送至过胶机，在第三电晕微孔面的表面涂布胶水，形成第二胶水复合面，以使胶水快速渗透进入以第三电晕微孔面的微型孔穴中；
复合处理，在完成二次过胶处理之后立即将经过养生处理的PVC复合层预制件贴附在经过二次过胶处理的防水基材复合层，PVC复合层预制件的第 一电晕微孔面复合于防水基材复合层的第二胶水复合面，得到复合板材；
冷压处理，在完成复合处理后立即将复合板材输送至冷压机内，将压力调至3-15Mpa，保压4-8小时，得到复合板材原板，放置一边备用；
后期加工，对复合板材原板进行后期加工，后期加工至少包括锯板加工、裁切加工和槽榫加工中的一种；
地板成品，经过后期加工得到成品防水耐磨复合地板。
进一步的技术方案，一种防水耐磨复合地板，包括防水基材层和软垫层，其特征在于：包括预先制作的通过热压工艺复合而成的PVC复合层预制件，PVC复合层预制件从上往下依次包括PVC耐磨层、PVC图案层和PVC塑料层，
经过表面电晕处理的PVC复合层预制件、经过表面电晕处理的软垫层和经过砂光处理的防水基材层三者一同通过热压工艺复合一防水耐磨复合地板；
PVC复合层预制件的下表面和软垫层的上下两个表面分别密集布满有上部具有一收缩型穴口、底部相互连通的微型孔穴；
软垫层的上表面热熔复合于PVC复合层预制件、下表面热熔复合于防水基材层，分别在PVC复合层预制件和软垫层的相接表面以下的层面中形成一连成一体的网格形状的复合材料粘结层，在软垫层和防水基材层的相接表面以下的层面中形成一连成一体的网格形状的复合材料粘结层。
本发明和现有技术相比所具有的优点是：
1、本发明工艺简单，易于实施，将防水耐磨复合地板的生产周期缩短至24～48小时，生产周期缩短70％，生产能耗降低70～80％，大幅度降低生产成本。
2、根据本发明生产的防水耐磨复合地板结构简单，具有非常好的防水性能和耐磨性能，防水耐磨复合地板不会产生鼓包，也不易分层或变形。
附图说明
下面结合附图和实施例对本发明进一步说明。
图1是根据本发明的生产方法所生产的第一种防水耐磨复合地板的结构示意图。
图2是根据本发明的生产方法所生产的第二种防水耐磨复合地板的结构示意图。
图中：
1、防水基材层11、槽榫。
2、软垫层21、复合材料粘结层22、贯穿孔。
3、PVC复合层预制件31、PVC耐磨层32、PVC图案层33、PVC塑料层。
具体实施方式
以下仅为本发明的较佳实施例，并不因此而限定本发明的保护范围。
实施例一
一种防水耐磨复合地板的生产方法，图1和2所示，包括以下步骤，
制作PVC复合层预制件，包括以下子步骤，
a)、PVC复合层胚制件复合子步骤，将PVC耐磨层31、PVC图案层32和PVC塑料层33一同输送至热压设备热压复合，且PVC耐磨层31叠置于PVC图案层32的上方，PVC图案层32叠置于于PVC塑料层33的上方，通过热压设备将PVC耐磨层31、PVC图案层32和PVC塑料层33热压复合成一体式的复合片材或复合膜材，从而得到PVC复合层胚制件；
b)、PVC复合层胚制件电晕子步骤，PVC复合层胚制件电晕处理，将PVC复合层胚制件输送至电晕加工设备，对PVC复合层胚制件的上表面进行电晕处理，以在PVC复合层胚制件的上表面形成一第一电晕微孔面，使PVC复合层胚制件的上表面布满直径为0.01-0.1mm的微型孔穴，PVC复合层胚制件的微型孔穴延伸到PVC复合层胚制件的深度为0.01-0.1mm，微型孔穴具有重要作用，与后续的一次电晕处理相同；
较佳的实施方式，对PVC复合层胚制件的下表面进行电晕处理，以在PVC复合层胚制件的下表面也形成一第一电晕微孔面。
c)、PVC复合层胚制件涂UV漆子步骤，在经过电晕处理的PVC复合层胚制件的上表面辊涂或喷涂UV漆，以形成一UV漆层34；UV漆渗透进入第一电晕微孔面中，使UV漆层34与PVC复合层胚制件之间粘结更牢固。
经过表面电晕处理的PVC复合层预制件3的下表面具有一电晕面，经过表面电晕处理的PVC复合层预制件3的下表面密集布满外端部为一收缩型穴口、底部为相互连通的微型孔穴；
软垫层2的上表面涂面胶水层，使PVC复合层预制件3的下表面更加牢固地复合在软垫层2的上表面；
d)、PVC复合层胚制件热处理子步骤，对PVC复合层胚制件进行热处理，先对PVC复合层胚制件进行加热，加热温度80～120℃，加热时间为1-10分钟，再将PVC复合层胚制件置于温度为10～25℃的温度环境中经过常温冷却，将其急速冷却，通过热处理消除PVC复合层胚制件存在的内应力，使PVC复合层胚制件的尺寸更加稳定，避免后续加工中产生翘曲或变形。
具体的实施方式中，通过输送带输送PVC复合层胚制件，使PVC复合层胚制件顺次通过隧道式烤箱和常温冷却水槽，从隧道式烤箱输送出来的PVC 复合层胚制件经由输送带输送立即进入常温冷却水槽，急速冷却1-10分钟，较佳的，将急速冷却时间控制在3-5分钟，以实现除内应力，防止翘曲。
优选的实施方式中，将隧道式烤箱内的温度控制在80～120℃，将PVC复合层胚制件通过隧道式烤箱的时间为控制在1-10分钟，即PVC复合层胚制件通过烤箱烘烤1-10分钟；较佳的，将烘烤时间控制在3-7分钟。
优选的实施方式中，将常温冷却水槽中的冷却水的温度控制在10～25℃，较佳的常温冷却水槽中的冷却水的温度控制20℃，在输送带输送PVC复合层胚制件通过常温冷却水槽的过程中PVC复合层胚制件局部或全部浸入在冷却水中，将PVC复合层胚制件浸入在冷却水中的时间控制在1-10分钟，即PVC复合层胚制件通过水冷方式冷却1-10分钟，通过水冷方式将PVC复合层胚制件的温度迅速降温至常温。
优选的实施方式中，在PVC复合层胚制件从常温冷却水槽出来后，快速吹干PVC复合层胚制件，具体是通过风扇吹PVC复合层胚制件，以实现快速吹干并去除PVC复合层胚制件表层的水。
e)、PVC复合层胚制件养生处理子步骤，将经过热处理的PVC复合层胚制件放置或堆垛于养生仓中，至少养生24小时，得到PVC复合层预制件3，放置一边备用，通过养生处理消除PVC复合层胚制件存在的少量内应力，防止在后续生产过程中出现翘曲，同时防止成品在经过使用后因存在内应力而出现翘曲；
一次电晕处理，将软垫层2输送至电晕加工设备，对软垫层2的下表面进行电晕处理，以在软垫层2的下表面形成第二电晕微孔面，第二电晕微孔面的表面布满直径为0.01-0.1mm的微型孔穴，第二电晕微孔面的微型孔穴延伸到软垫层2的深度为0.01-0.1mm；
其中，本发明是在电晕设备设置一电晕平台，在电晕设备的上方安装有一能够沿电晕平台前后移动的横臂，横臂横向跨过输送平台，在横臂安装有至少一排电晕单元，第一排电晕单元紧密排列有多个电晕喷头，每一个电晕喷头的底面设置有密集排列的纤维束；
在电晕过程中，将各电晕喷头的底面与放置在电晕平台的软垫层2的距离控制在0.5-5cm，控制横臂沿输送台移动，使各电晕喷头从电晕平台的一侧移动至另一侧；
在电晕过程对电晕单元提供高频交流电压并使各电晕喷头的底面朝向电晕平台连续喷射密集的电晕，电晕喷头发射的电晕击穿软垫层2的表面，从而在软垫层2的表面形成密集的微型孔穴，实现对软垫层2的上表面的电晕处理。
优选的实施方式中，在电晕设备固定一金属托板作为电晕平台，并将金属托板电连接直流正电极，将金属托板的表面电压控制在0.5～48V；
在每一个电晕单元的上部固定有超声波变频杆，将各电晕喷头分别设置成超声波定向发射头，通过超声波发生器分别对各超声波变频杆提供超声波，以实现将超声波传导至各电晕单元，通过各电晕喷头分别朝向金属托板定向发射第一超声波，且每一个电晕喷头射出的电晕均与该电晕喷头射出的第一超声波相互重叠；
通过金属托板反射第一超声波，使反射的第一超声波汇集在软垫层2中并在软垫层2中产生空化效应，空化效应将各穴腔的侧壁破碎成粉末。较佳的，本发明在各穴腔内分别保留由其侧壁经过空化破碎而形成的软垫层2粉末。
在软垫层2超声复合处理中，胶水分别渗透到各相应的穴腔中，胶水和 软垫层2粉末分别渗透到相应的防水基材层1的表面以下的纤维间隙中，从而分别在软垫层2的表面以下的层面中以及防水基材层1的表面以下的层面中形成一连成一体的网格形状的复合材料粘结层21。
通过带有正电压的金属托板，使经由金属托板反射而回的第一超声波与正向发射的第一超声波以及正向发射的电晕在软垫层2的上表面形成一冲击界面，进而使空化效应的产生区域集中控制在软垫层2的上表面以下的层面中，从而在垫层的上表面以下0.01～0.1mm的层面中产生密集的微型孔穴；
使形成在软垫层2的上表面的每一个微型孔穴均具有一穴腔和一收缩型穴口，穴腔和收缩型穴口主要由电晕击穿而产生，第一超声波使穴腔内产生空化效应而扩大穴腔的体积，且在扩腔的过程中使收缩型穴口的大小保持不变。
空化效应与电晕，将各微型孔穴的局部侧壁击穿，在各穴腔的侧壁分别形成至少一微型连贯穿孔，使各微型孔穴的穴腔分别局部相连通，而微型孔穴上部的收缩型穴口仍然保留完整侧壁，以分别间隔开各微型孔穴；
相邻贯穿孔22的穴腔连通贯穿孔22，使软垫层2表面的各微型孔穴的穴腔分别通过相应的微型连贯穿孔分别连通相应的贯穿孔22，以形成一由微型排气间隙、微型孔穴和贯穿孔22互连而成的立体的排气网络。通过贯穿孔22快速排除软垫层2以及其相接界面中的空气，避免在相接界面或邻近的层面中存留空气，从而有效避免防水耐磨复合地板产生鼓包。具体的，贯穿孔22的直径或宽度为2～20mm；较佳的，贯穿孔22的直径或宽度为5～10mm。
裁切，将经过电晕处理的软垫层2输送至裁切设备进行裁切，使软垫层2形状与PVC复合层预制件3的形状相匹配，或者使软垫层2形状与防水基材层1的形状相匹配；
冲孔处理，将软垫层2输送至冲孔设备进行冲孔，至少使软垫层2的中部区域布满多个贯穿孔22，各贯穿孔22分别上下贯穿软垫层2，得到带孔软垫层。
其中，软垫层2选用EVA片材、EVA膜材、IXPE片材、IXPE膜材、IXPP片材、IXPP膜材、PP片材、PP膜材、PVC片材或PVC膜材。
较佳的，软垫层2优选EVA片材或EVA膜材，冲孔处理使软垫层2的中部布满贯穿孔22。
防水基材层砂光处理，将防水基材层1输送至砂光设备，对防水基材层1的上表面进行砂光处理，以形成一平整的砂光面。
粉尘去除步骤，通过气枪吹除防水基材层的砂光面表面的粉尘，或者，通过毛刷扫除或吸附防水基材层的砂光面表面的粉尘，或者，通过吸尘设备吸除防水基材层的砂光面表面的粉尘，避免粉尘四处飞扬。然后在砂光面辊涂、辊涂或喷涂有一层硅烷偶联剂稀释液，将硅烷偶联剂与水按比例稀释得到硅烷偶联剂稀释液，硅烷偶联剂在硅烷偶联剂稀释液中的重量百分比为1-5％。
烘干步骤，对经过粉尘去除步骤的砂光面进行烘干，烘干温度控制在80-100℃，烘干时间控制在5-15钟。经过烘干处理，去除涂布在砂光面之上的硅烷偶联剂稀释液中的水份，在砂光面的表面形成一稀薄的由硅烷偶联剂构成的硅烷偶联剂粘合层，硅烷偶联剂粘合层渗透进入到砂光面的表面以下，硅烷偶联剂粘合层提高防水基材层与带孔软垫层之间的复合牢固度。与没有硅烷偶联剂粘合层的技术方案相比较，具有硅烷偶联剂粘合层的技术方案能将其复合牢固度提高2-4倍。
过胶处理，将防水基材层1输送至过胶机，在防水基材层1的砂光面涂 布胶水，在防水基材层1的砂光面之上形成第一胶水复合面；
复合软垫层，将带孔软垫层贴附在防水基材层1表面，且带孔软垫层的第二电晕微孔面对应复合贴附于防水基材层1的第一胶水复合面，得到防水基材初步复合层，放置一边备用；
软垫层超声复合处理，将防水基材初步复合层输送到安装有超声压板的超声波压机，将防水基材初步复合层置于超声压贴平台，控制超声压贴平台上方的超声压板向下移动并压贴于防水基材初步复合层的带孔软垫层之上，对超声压板通电，将超声压板的温度提升至80～120℃，同时开启超声发生器，通过安装在超声压板背部的超声变频杆将超声波传导至超声压板，超声压板再将超声波传导至带孔软垫层以及带孔软垫层与防水基材层1之间的复合界面，进行超声热复合，超声热复合过程包括三个子步骤：
a、胶水渗透子步骤，控制超声压板轻压带孔软垫层，在温度和超声波共同作用下，胶水分别快速渗透进入带孔软垫层和防水基材层1，
具体的，将超声压板对带孔软垫层的压力控制在0.5-0.8Mpa，在温度和超声波作用下，传导至胶水中超声波产生机械效应和温热效应，提升胶水中水分子及高份子化合物的分子运动，在提升胶水的温度的同时使胶水在软化，提升胶水的流动性，传导至胶水中超声波同时产生理化效应，对胶水产生弥散作用和触变作用，弥散作用提升带孔软垫层和胶水的渗透性，触变作用使胶水分化成粒为0.01-0.1mm的小粒径颗粒，使胶水分别快速渗透进入第二电晕微孔面的微型孔穴中和防水基材层1的表面以下的纤维间隙中，在防水基材层1的表面以下的层面中形成一由软垫层2粉末、胶水、防水基材层1中的纤维以及存在于防水基材层1中的填料相互渗透而成且连成一体的复合材料粘结层21；
防水基材层1选用防水复合板材，防水复合板材至少包括木塑板材、石塑板材、塑料板材、防水复合木板中的一种。
从材料层结构区分，防水复合板材可以是仅具有单层结构的板材，也可以是具有至少两个层结构的复合板材。
较佳的，防水基材层1选用木塑板材、石塑板材或防水复合木板。
当然，防水基材层1也可以选用塑料板材，在进行软垫层2超声复合处理之前对塑料板材的上表面进行电晕处理，使塑料板材的上表面布满微型孔穴，处理过程与一次电晕处理相同。
b、气体排空子步骤，在完成胶水渗透之后，逐渐增加超声压板的压力，在压力和超声波共同作用下，将带孔软垫层与防水基材层1的相接界面的空气分别通过微型孔穴及贯穿孔22排挤出去，
具体的，逐渐增加超声压板的压力，压力控制在0.5-2Mpa，在压力和超声波作用下，带孔软垫层贴附于防水基材层1的一面的空气分别通过各微型孔穴及贯穿孔22排出，避免带孔软垫层与防水基材层1之间产生鼓包；
c、超声热复合子步骤，在排空相接界面的空气之后，控制超声压板保持设定的压力和温度，在温度、压力和超声波共同作用下，使第二电晕微孔面渗透到防水基材层1的表面以下，使带孔软垫层牢固复合在防水基材层1的上表面，得到防水基材复合层；
具体的，在温度、压力和超声波共同作用下，先使渗透到各软垫层2粉末、胶水以及存在于防水基材层1中的填料转变成微融状态，以形成一复合材料混合层，再使复合材料混合层在保压时固化，最终形成一复合材料粘结层21，从而使带孔软垫层牢固复合在防水基材层1的上表面，得到防水基材复合层。
二次电晕处理，将防水基材复合层输送至一次电晕处理中所使用的电晕设备，对防水基材复合层上方的软垫层2的上表面进行电晕处理，以形成第三电晕微孔面，第三电晕微孔面的表面布满直径为0.01-0.1mm的微型孔穴，第三电晕微孔面的微型孔穴伸入到软垫层2的深度为0.01-0.1mm；二次电晕处理的过程与一次电晕处理的过程相同，其区别之处仅是电晕对象不同，这里不再赘述。
二次过胶处理，在防水基材复合层完成二次电晕处理后立即将防水基材复合层输送至过胶机，在第三电晕微孔面的表面涂布胶水，形成第二胶水复合面，以使胶水快速渗透进入以第三电晕微孔面的微型孔穴中。
复合处理，在完成二次过胶处理之后立即将经过养生处理的PVC复合层预制件3贴附在经过二次过胶处理的防水基材复合层，PVC复合层预制件3的第一电晕微孔面复合于防水基材复合层的第二胶水复合面，得到复合板材；
冷压处理，在完成复合处理后立即将复合板材输送至冷压机内，将压力调至3-15Mpa，保压4-8小时，得到复合板材原板，放置一边备用；
具体的，冷压机设置有超声冷压平台，超声冷压平台上方安装有超声冷压板，将复合板材置于超声冷压平台，控制超声冷压板向下移动并压贴于复合板材的背面，将超声冷压板的压力控制在1-10Mpa，同时开启超声发生器，在压力和超声波共同作用下，通过安装在超声冷压板上部的超声变频杆将超声波传导至超声冷压板，超声冷压板再将超声波传导至复合板材，进行超声冷压复合，使存留在带孔软垫层的内部以及上下两侧的空气通过贯穿孔22及微型孔穴排出到复合板材外部。
本发明是先制作PVC复合层预制件，再对软垫层进行电晕处理和冲孔处理，最后将PVC复合层预制件、软垫层和防水基材层一次性复合成一体，制 成的防水耐磨复合地板包括位于上层的PVC复合层预制件3、位于中间层的带孔软垫层和位于下层的防水基材复合层，且PVC复合层预制件3、带孔软垫层和防水基材复合层复合成一体。
后期加工，对复合板材原板进行后期加工，后期加工至少包括锯板加工、裁切加工、槽榫加工中的一种；
地板成品，经过后期加工得到成品防水耐磨复合地板；制成的所述防水耐磨复合地板包括位于上层的PVC复合层预制件3、位于中间层的带孔软垫层和位于下层的防水基材复合层，且PVC复合层预制件3、带孔软垫层和防水基材复合层复合成一体。
本发明工艺简单，易于实施，将防水耐磨复合地板的生产周期缩短至24～48小时，生产周期缩短70％，生产能耗降低70～80％，大幅度降低生产成本。根据本发明生产的防水耐磨复合地板结构简单，具有非常好的防水性能和耐磨性能，防水耐磨复合地板不会产生鼓包，也不易分层或变形。
实施例二
一种防水耐磨复合地板，图1所示，包括防水基材层1、软垫层2和预先制作的通过热压工艺复合而成的PVC复合层预制件3，PVC复合层预制件3从上往下依次包括PVC耐磨层31、PVC图案层32和PVC塑料层33。
本实施例的主要结构与实施例一相同。图1所示是根据本发明的生产方法所生产的第一种防水耐磨复合地板的结构示意图。
其中，PVC复合层预制件3是片材或膜材，PVC塑料层33选用PVC片材或PVC膜材。PVC复合层预制件3是一个预制件，具有极薄的厚度，具有非常好的防水性能和耐磨性能，PVC复合层预制件3的设计能够减少生产防 水耐磨复合地板所需的多个表面复合工序，将其生产时间(生产周期)缩短一半，同时相应的，能够使防水耐磨复合地板的生产成本降低一半。
PVC复合层预制件3的总厚度为0.5-2.5mm，较佳的，PVC复合层预制件3的总厚度为0.5-1.2mm。其中，PVC塑料层33的厚度控制在0.6-1.5mm，较佳的，PVC塑料层33的厚度控制在0.6-1.2mm。
软垫层2选用具有弹性的塑料层，例如软垫层2选用EVA片材、EVA膜材、IXPE片材、IXPE膜材、IXPP片材、IXPP膜材、PP片材、PP膜材、PVC片材或PVC膜材。
较佳的，软垫层2选用EVA片材、EVA膜材，软垫层2的厚度为0.5-2.5mm，较佳的，将软垫层2的厚度控制在0.8-1.2mm，既能降低防水耐磨复合地板的总厚度以降低其成本，同时使防水耐磨复合地板和我有更好的平衡性。
具体的，经过表面电晕处理的PVC复合层预制件3的下表面具有一电晕面，经过表面电晕处理的PVC复合层预制件3的下表面密集布满外端部为一收缩型穴口、底部为相互连通的微型孔穴。经过表面电晕处理的软垫层2的上下表面分别具有一电晕面，经过表面电晕处理的软垫层2的上表面和和下表面分别密集布满外端部为一收缩型穴口、底部为相互连通的微型孔穴。其中，微型孔穴的直径为0.01-0.1mm，微型孔穴的的深度为0.01-0.1mm。
防水基材层1的厚度为3-15mm，较佳的，将防水基材层1的厚度控制在4-8mm，以作为地板主体层，并能够在其侧面开设槽榫11。防水基材层1选用防水复合板材，防水复合板材至少包括木塑板材、石塑板材、塑料板材、防水复合木板中的一种。较佳的，防水基材层1选防水复合木板或防水复合纤维板。
经过砂光处理的防水基材层1的上表面具有砂光面。较佳的，在砂光面 的表面涂布硅烷偶联剂稀释液并烘干，以在在砂光面的表面形成一硅烷偶联剂粘合层。
软垫层2的的下表面通过超声热复合工艺复合于防水基材层1的上表面，PVC复合层预制件3的下表面通过冷压工艺复合于软垫层2的上表面，
软垫层2和防水基材层1的相接表面以下的层面中形成一连成一体的网格形状的复合材料粘结层21，其复合材料粘结层21的上下两面分别延伸到复合软垫层2和防水基材层1中，在表面粘贴复合的基础上具有物理咬合的连接作用，能够更加牢固地复合软垫层2和防水基材层1，软垫层2和防水基材层1之间不易分层，也不易产生变形。
在PVC复合层预制件3和软垫层2的相接表面以下的层面中形成一连成一体的网格形状的复合材料粘结层21；其复合材料粘结层21的上下两面分别延伸到PVC复合层预制件3和软垫层2中，在表面粘贴复合的基础上具有物理咬合的连接作用，能够更加牢固地复合PVC复合层预制件3和软垫层2，PVC复合层预制件3和软垫层2之间不易分层。
软垫层2的中间区域布满有多个上下贯穿软件层的贯穿孔22。贯穿孔22的直径或宽度为2～20mm；较佳的，贯穿孔22的直径或宽度为5～10mm。在复合过程中，通过贯穿孔22快速排除软垫层2以及其相接界面中的空气，避免在相接界面或邻近的层面中存留空气，从而有效避免防水耐磨复合地板产生鼓包。
防水耐磨复合地板的侧面设有槽榫11，槽榫11仅开设在防水基材层1的侧面。贯穿孔22开设有软垫层2没有开设槽榫11的区域或位置，贯穿孔22远离槽榫11。
实施例三
一种防水耐磨复合地板，图2所示，包括防水基材层1、软垫层2和预先制作的通过热压工艺复合而成的PVC复合层预制件3，PVC复合层预制件3从上往下依次包括PVC耐磨层31、PVC图案层32和PVC塑料层33。
本实施例的主要结构与实施例一相同。图2所示是根据本发明的生产方法所生产的第二种防水耐磨复合地板的结构示意图。
经过表面电晕处理的软垫层2的上表面和和下表面分别密集布满外端部为一收缩型穴口、底部为相互连通的微型孔穴。同时，防水基材层1的上表面涂有胶水层，使软垫层2的下表面更加牢固地复合在防水基材层1的上表面。
软垫层2和防水基材层1的相接表面以下的层面中形成一连成一体的网格形状的复合材料粘结层21，其复合材料粘结层21的上下两面分别延伸到复合软垫层2和防水基材层1中，在表面粘贴复合的基础上具有物理咬合的连接作用，能够更加牢固地复合软垫层2和防水基材层1，软垫层2和防水基材层1之间不易分层，也不易产生变形。
在PVC复合层预制件3的上表面涂有UV漆层34，UV漆层34除了使PVC复合层预制件具有较好的装饰性之处，还具有较好的耐磨性。
经过表面电晕处理的PVC复合层预制件3的下表面具有一电晕面，经过表面电晕处理的PVC复合层预制件3的下表面密集布满外端部为一收缩型穴口、底部为相互连通的微型孔穴。软垫层2的上表面涂面胶水层，使PVC复合层预制件3的下表面更加牢固地复合在软垫层2的上表面。
在PVC复合层预制件3和软垫层2的相接表面以下的层面中形成一连成一体的网格形状的复合材料粘结层21；其复合材料粘结层21的上下两面分别 延伸到PVC复合层预制件3和软垫层2中，在表面粘贴复合的基础上具有物理咬合的连接作用，能够更加牢固地复合PVC复合层预制件3和软垫层2，PVC复合层预制件3和软垫层2之间不易分层。
软垫层2的中间区域布满有多个上下贯穿软件层的贯穿孔22。在复合过程中，通过贯穿孔22快速排除软垫层2以及其相接界面中的空气，避免在相接界面或邻近的层面中存留空气，从而有效避免防水耐磨复合地板产生鼓包。
防水耐磨复合地板的侧面设有槽榫11，槽榫11仅开设在防水基材层1的侧面。贯穿孔22开设有软垫层2没有开设槽榫11的区域或位置，贯穿孔22远离槽榫11。
防水基材层1的底面复合有一弹性层4，弹性层4选用软木材料复合层、IXPE或EVA，弹性层4的厚度为1-5mm，较佳的，弹性层4的厚度控制在1-2mm，以使复合地板具有较好的平衡性和缓冲性，提高复合地板的舒适性，弹性层4同时使防水耐磨复合地板具有较好的吸音性能，使其具有静音效果。
以上内容仅为本发明的较佳实施例，对于本领域的普通技术人员，依据本发明的思想，在具体实施方式及应用范围上均会有改变之处，本说明书内容不应理解为对本发明的限制。

Claims (10)

  1. 一种防水耐磨复合地板的生产方法，其特征在于，包括以下步骤：
    制作PVC复合层预制件，包括以下子步骤，
    a)、PVC复合层胚制件复合子步骤，将PVC耐磨层(31)、PVC图案层(32)和PVC塑料层(33)一同输送至热压设备热压复合，且PVC耐磨层(31)叠置于PVC图案层(32)的上方，PVC图案层(32)叠置于于PVC塑料层(33)的上方，通过热压设备将PVC耐磨层(31)、PVC图案层(32)和PVC塑料层(33)热压复合成一体式的复合片材或复合膜材，从而得到PVC复合层胚制件；
    b)、PVC复合层胚制件电晕子步骤，PVC复合层胚制件电晕处理，将PVC复合层胚制件输送至电晕加工设备，对PVC复合层胚制件的上表面和/或下表面进行电晕处理，以在PVC复合层胚制件的上表面和/或下表面形成一第一电晕微孔面，使PVC复合层胚制件的上表面和/或下表面布满直径为0.01-0.1mm的微型孔穴，PVC复合层胚制件的微型孔穴延伸到PVC复合层胚制件的深度为0.01-0.1mm；
    c)、PVC复合层胚制件涂UV漆子步骤，在经过电晕处理的PVC复合层胚制件的上表面辊涂或喷涂UV漆，以形成一UV漆层(34)；
    d)、PVC复合层胚制件热处理子步骤，对PVC复合层胚制件进行热处理，先对PVC复合层胚制件进行加热，加热温度80～120℃，加热时间为1-10分钟，再将PVC复合层胚制件置于温度为10～25℃的温度环境中经过常温冷却，将其急速冷却1-10分钟；
    e)、PVC复合层胚制件养生处理子步骤，将经过热处理的PVC复合层胚制件放置或堆垛于养生仓中，至少养生24小时，得到PVC复合层预制件(3)，放置一边备用；
    一次电晕处理，将软垫层(2)输送至电晕加工设备，对软垫层(2)的下表面进行电晕处理，以在软垫层(2)的下表面形成第二电晕微孔面，第二电晕微孔面的表面布满直径为0.01-0.1mm的微型孔穴，第二电晕微孔面的微型孔穴延伸到软垫层(2)的深度为0.01-0.1mm；
    裁切，将经过电晕处理的软垫层(2)输送至裁切设备进行裁切，使软垫层(2)形状与PVC复合层预制件(3)的形状相匹配，或者使软垫层(2)形状与防水基材层(1)的形状相匹配；
    防水基材层砂光处理，将防水基材层(1)输送至砂光设备，对防水基材层(1)的上表面进行砂光处理，以形成一平整的砂光面；
    过胶处理，将防水基材层(1)输送至过胶机，在防水基材层(1)的砂光面涂布胶水，在防水基材层(1)的砂光面之上形成第一胶水复合面；
    复合软垫层，将带孔软垫层贴附在防水基材层(1)表面，且带孔软垫层的第二电晕微孔面对应复合贴附于防水基材层(1)的第一胶水复合面，得到防水基材初步复合层，放置一边备用；
    软垫层超声复合处理，将防水基材初步复合层输送到安装有超声压板的超声波压机，将防水基材初步复合层置于超声压贴平台，控制超声压贴平台上方的超声压板向下移动并压贴于防水基材初步复合层的带孔软垫层之上，对超声压板通电，将超声压板的温度提升至80～120℃，同时开启超声发生器，通过安装在超声压板背部的超声变频杆将超声波传导至超声压板，超声压板再将超声波传导至带孔软垫层以及带孔软垫层与防水基材层(1)之间的复合界面，进行超声热复合，超声热复合过程包括三个子步骤：
    a)、胶水渗透子步骤，控制超声压板轻压带孔软垫层，在温度和超声波共同作用下，胶水分别快速渗透进入带孔软垫层和防水基材层(1)，
    b)、气体排空子步骤，在完成胶水渗透之后，逐渐增加超声压板的压力，在压力和超声波共同作用下，将带孔软垫层与防水基材层(1)的相接界面的空气分别通过微型孔排挤出去，
    c)、超声热复合子步骤，在排空相接界面的空气之后，控制超声压板保持设定的压力和温度，在温度、压力和超声波共同作用下，使第二电晕微孔面渗透到防水基材层(1)的表面以下，使带孔软垫层牢固复合在防水基材层(1)的上表面，得到防水基材复合层；
    二次电晕处理，将防水基材复合层输送至电晕设备，对防水基材复合层上方的软垫层(2)的上表面进行电晕处理，以形成第三电晕微孔面，第三电晕微孔面的表面布满直径为0.01-0.1mm的微型孔穴，第三电晕微孔面的微型孔穴伸入到软垫层(2)的深度为0.01-0.1mm；
    二次过胶处理，在防水基材复合层完成二次电晕处理后立即将防水基材复合层输送至过胶机，在第三电晕微孔面的表面涂布胶水，形成第二胶水复合面，以使胶水快速渗透进入以第三电晕微孔面的微型孔穴中；
    复合处理，在完成二次过胶处理之后立即将经过养生处理的PVC复合层预制件(3)贴附在经过二次过胶处理的防水基材复合层，PVC复合层预制件(3)的第一电晕微孔面复合于防水基材复合层的第二胶水复合面，得到复合板材；
    冷压处理，在完成复合处理后立即将复合板材输送至冷压机内，将压力调至3-15Mpa，保压4-8小时，得到复合板材原板，放置一边备用；
    后期加工，对复合板材原板进行后期加工，后期加工至少包括锯板加工、裁切加工和槽榫加工中的一种；
    地板成品，经过后期加工得到成品防水耐磨复合地板。
  2. 根据权利要求1所述的一种防水耐磨复合地板的生产方法，其特征在于：在所述过胶处理之前增加一冲孔处理步骤，
    冲孔处理步骤，将软垫层(2)输送至冲孔设备进行冲孔，至少使软垫层(2)的中部区域布满多个贯穿孔(22)，各贯穿孔(22)分别上下贯穿软垫层(2)，得到带孔软垫层；
    在所述气体排空子步骤中，带孔软垫层与所述防水基材层(1)的相接界面的空气分别通过微型孔穴及贯穿孔(22)排挤出去；
    在所述冷压处理中，冷压机设置有超声冷压平台，超声冷压平台上方安装有超声冷压板，将复合板材置于超声冷压平台，控制超声冷压板向下移动并压贴于复合板材的背面，将超声冷压板的压力控制在1-10Mpa，同时开启超声发生器，在压力和超声波共同作用下，通过安装在超声冷压板上部的超声变频杆将超声波传导至超声冷压板，超声冷压板再将超声波传导至复合板材，进行超声冷压复合，使存留在带孔软垫层的内部以及上下两侧的空气通过贯穿孔(22)及微型孔穴排出到复合板材外部；
    制成的所述防水耐磨复合地板包括位于上层的PVC复合层预制件(3)、位于中间层的带孔软垫层和位于下层的防水基材复合层，且PVC复合层预制件(3)、带孔软垫层和防水基材复合层复合成一体；
    在所述PVC复合层胚制件热处理子步骤中，通过输送带输送PVC复合层胚制件，使PVC复合层胚制件顺次通过隧道式烤箱和常温冷却水槽，从隧道式烤箱输送出来的PVC复合层胚制件经由输送带输送立即进入常温冷却水槽；
    将隧道式烤箱内的温度控制在80～120℃，将PVC复合层胚制件通过隧道式烤箱的时间为控制在1-10分钟；
    将常温冷却水槽中的冷却水的温度控制在10～25℃，在输送带输送PVC复合层胚制件通过常温冷却水槽的过程中PVC复合层胚制件局部或全部浸入在冷却水中，将PVC复合层胚制件浸入在冷却水中的时间控制在1-10分钟，通过水冷方式将PVC复合层胚制件的温度迅速降温至常温；
    在所述防水基材层砂光处理步骤和过胶处理步骤之间增加一粉尘去除步骤和烘干步骤，
    粉尘去除步骤，通过气枪吹除防水基材层的砂光面表面的粉尘，然后在砂光面涂布至少一层硅烷偶联剂稀释液，将硅烷偶联剂与水按比例稀释得到硅烷偶联剂稀释液，硅烷偶联剂在硅烷偶联剂稀释液中的重量百分比为1-5％；
    烘干步骤，对经过粉尘去除步骤的砂光面进行烘干，烘干温度控制在80-100℃，烘干时间控制在5-15钟。
  3. 根据权利要求1所述的一种防水耐磨复合地板的生产方法，其特征在于：在所述一次电晕处理和所述二次电晕处理中，
    在所述电晕设备设置一电晕平台，
    在电晕设备的上方安装有一能够沿电晕平台前后移动的横臂，横臂横向跨过输送平台，在横臂安装有至少一排电晕单元，第一排电晕单元紧密排列有多个电晕喷头，每一个电晕喷头的底面设置有密集排列的纤维束；
    在电晕过程中，将各电晕喷头的底面与放置在电晕平台的软垫层(2)的距离控制在0.5-5cm，控制横臂沿输送台移动，使各电晕喷头从电晕平台的一侧移动至另一侧；
    在电晕过程对电晕单元提供高频交流电压并使各电晕喷头的底面朝向电晕平台连续喷射密集的电晕，电晕喷头发射的电晕击穿软垫层(2)的表面，从而在软垫层(2)的表面形成密集的微型孔穴，实现对软垫层(2)的上表 面的电晕处理。
  4. 根据权利要求3所述的一种防水耐磨复合地板的生产方法，其特征在于：在所述一次电晕处理和所述二次电晕处理中，
    在所述电晕设备固定一金属托板作为电晕平台，并将所述金属托板电连接直流正电极，将金属托板的表面电压控制在0.5～48V；
    在每一个所述电晕单元的上部固定有超声波变频杆，将各电晕喷头分别设置成超声波定向发射头，通过超声波发生器分别对各超声波变频杆提供超声波，以实现将超声波传导至各电晕单元，通过各电晕喷头分别朝向金属托板定向发射第一超声波，且每一个电晕喷头射出的电晕均与该电晕喷头射出的第一超声波相互重叠；
    通过金属托板反射第一超声波，使反射的第一超声波汇集在软垫层(2)中并在软垫层(2)中产生空化效应，
    通过带有正电压的金属托板，使经由金属托板反射而回的第一超声波与正向发射的第一超声波以及正向发射的电晕在软垫层(2)的上表面形成一冲击界面，进而使空化效应的产生区域集中控制在软垫层(2)的上表面以下的层面中，从而在垫层的上表面以下0.01～0.1mm的层面中产生密集的微型孔穴；
    使形成在软垫层(2)的上表面的每一个微型孔穴均具有一穴腔和一收缩型穴口，穴腔和收缩型穴口主要由电晕击穿而产生，第一超声波使穴腔内产生空化效应而扩大穴腔的体积，且在扩腔的过程中使收缩型穴口的大小保持不变。
  5. 根据权利要求4所述的一种防水耐磨复合地板的生产方法，其特征在于：所述空化效应中，在各所述穴腔内分别保留由其侧壁经过空化破碎而形成的软垫层(2)粉末，
    在所述软垫层(2)超声复合处理中，所述胶水分别渗透到各相应的穴腔中，胶水和软垫层(2)粉末分别渗透到相应的防水基材层(1)的表面以下的纤维间隙中，从而分别在软垫层(2)的表面以下的层面中以及防水基材层(1)的表面以下的层面中形成一连成一体的网格形状的复合材料粘结层(21)。
  6. 根据权利要求5所述的一种防水耐磨复合地板的生产方法，其特征在于：在所述一次电晕处理和所述二次电晕处理中，所述空化效应与所述电晕，将各所述微型孔穴的局部侧壁击穿，在各穴腔的侧壁分别形成至少一微型连贯穿孔，使各微型孔穴的穴腔分别局部相连通，而微型孔穴上部的收缩型穴口仍然保留完整侧壁，以分别间隔开各微型孔穴；
    相邻所述贯穿孔(22)的穴腔连通贯穿孔(22)，使软垫层(2)表面的各微型孔穴的穴腔分别通过相应的微型连贯穿孔分别连通相应的贯穿孔(22)。
  7. 根据权利要求6所述的一种防水耐磨复合地板的生产方法，其特征在于：在所述软垫层(2)超声复合处理中，具体包括，
    a)、胶水渗透子步骤，将超声压板对带孔软垫层的压力控制在0.5-0.8Mpa，在温度和超声波作用下，传导至胶水中超声波产生机械效应和温热效应，提升胶水中水分子及高份子化合物的分子运动，在提升胶水的温度的同时使胶水在软化，提升胶水的流动性，传导至胶水中超声波同时产生理化效应，对胶水产生弥散作用和触变作用，弥散作用提升带孔软垫层和胶水的渗透性，触变作用使胶水分化成粒为0.01-0.1mm的小粒径颗粒，使胶水分别快速渗透进入所述第二电晕微孔面的微型孔穴中和防水基材层(1)的表面以下的纤维间隙中，在防水基材层(1)的表面以下的层面中形成一由软垫层(2)粉末、 胶水、防水基材层(1)中的纤维以及存在于防水基材层(1)中的填料相互渗透而成且连成一体的复合材料粘结层(21)；
    b)、气体排空子步骤，逐渐增加超声压板的压力，压力控制在0.5-2Mpa，在压力和超声波作用下，带孔软垫层贴附于防水基材层(1)的一面的空气分别通过各微型孔穴及贯穿孔(22)排出，避免带孔软垫层与防水基材层(1)之间产生鼓包，
    c)、超声热复合子步骤，在温度、压力和超声波共同作用下，先使渗透到各软垫层(2)粉末、胶水以及存在于防水基材层(1)中的填料转变成微融状态，以形成一复合材料混合层，再使复合材料混合层在保压时固化，最终形成一所述复合材料粘结层(21)，从而使带孔软垫层牢固复合在防水基材层(1)的上表面，得到防水基材复合层；
    所述软垫层(2)选用EVA片材或EVA膜材、IXPE片材、IXPE膜材、IXPP片材、IXPP膜材、PP片材、PP膜材、PVC片材、PVC膜材、软垫层(2)的中部布满贯穿孔(22)；
    所述防水基材层(1)选用防水复合板材，防水复合板材至少包括木塑板材、石塑板材、塑料板材、防水复合木板中的一种。
  8. 一种防水耐磨复合地板，包括防水基材层(1)和软垫层(2)，其特征在于：包括预先制作的通过热压工艺复合而成的PVC复合层预制件(3)，PVC复合层预制件(3)从上往下依次包括PVC耐磨层(31)、PVC图案层(32)和PVC塑料层(33)，
    经过表面电晕处理的PVC复合层预制件(3)、经过表面电晕处理的软垫层(2)和经过砂光处理的防水基材层(1)三者一同通过热压工艺复合一防水耐磨复合地板；
    PVC复合层预制件(3)的下表面和软垫层(2)的上下两个表面分别密集布满有上部具有一收缩型穴口、底部相互连通的微型孔穴；
    软垫层(2)的上表面热熔复合于PVC复合层预制件(3)、下表面热熔复合于防水基材层(1)，分别在PVC复合层预制件(3)和软垫层(2)的相接表面以下的层面中形成一连成一体的网格形状的复合材料粘结层(21)，在软垫层(2)和防水基材层(1)的相接表面以下的层面中形成一连成一体的网格形状的复合材料粘结层(21)。
  9. 根据权利要求8所述的一种防水耐磨复合地板，其特征在于：所述软垫层(2)选用EVA片材、EVA膜材、IXPE片材、IXPE膜材、IXPP片材、IXPP膜材、PP片材、PP膜材、PVC片材或PVC膜材，至少在软垫层(2)的中间区域布满有多个上下贯穿软件层的贯穿孔(22)；软垫层(2)的四周边缘或开设槽榫(11)的位置不开设贯穿孔(22)；防水耐磨复合地板的侧面设有槽榫(11)，槽榫(11)仅开设在防水基材层(1)的侧面。
  10. 根据权利要求9所述的一种防水耐磨复合地板，其特征在于：所述PVC复合层预制件(3)是一PVC片材或PVC膜材，所述PVC塑料层(33)选用PVC片材或PVC膜材，PVC复合层预制件(3)的总厚度为0.5-2.5mm，PVC塑料层(33)的厚度为0.6-1.5mm；所述防水基材层(1)选用防水复合板材，防水复合板材至少包括木塑板材、石塑板材、塑料板材、防水复合木板中的一种，防水基材层(1)的底面复合有弹性层(4)，弹性层(4)选用软木材料复合层、IXPE或EVA，弹性层(4)的厚度为1-5mm；防水基材层(1)的厚度为3-15mm，所述软垫层(2)的厚度为0.5-2.5mm；所述贯穿孔(22)的直径或宽度为2～20mm。
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