WO2021031289A1 - 一种共挤spc发泡地板及其制造方法 - Google Patents

一种共挤spc发泡地板及其制造方法 Download PDF

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Publication number
WO2021031289A1
WO2021031289A1 PCT/CN2019/107717 CN2019107717W WO2021031289A1 WO 2021031289 A1 WO2021031289 A1 WO 2021031289A1 CN 2019107717 W CN2019107717 W CN 2019107717W WO 2021031289 A1 WO2021031289 A1 WO 2021031289A1
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Prior art keywords
layer
foamed
spc
extruded
roller
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PCT/CN2019/107717
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English (en)
French (fr)
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宋剑刚
符家进
刘福清
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浙江永裕家居股份有限公司
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Application filed by 浙江永裕家居股份有限公司 filed Critical 浙江永裕家居股份有限公司
Priority to US17/783,880 priority Critical patent/US20230064465A1/en
Priority to EP19941984.7A priority patent/EP4039469A4/en
Publication of WO2021031289A1 publication Critical patent/WO2021031289A1/zh

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Abstract

本发明涉及一种发泡地板，尤其是SPC发泡地板及其制造方法。一种SPC发泡地板，包括石塑基材结构，所述石塑基材结构从上到下依次包括第一稳定层、发泡层和第二稳定层；第一稳定层和第二稳定层均为以PVC树脂和填料粉为主要成分的片材；其中PVC树脂的质量份为25~40，填料粉的质量份为55~75；所述SPC发泡地板的密度为1.4~1.6g/cm3。本发明通过在两个稳定层之间设置发泡层，显著地降低了地板的整体密度，达到1.4~1.6 g/m3，由于发泡层设置在内部，并不影响整体地板的表强；此外，试验证明本发明在尺寸稳定性上还得到了显著的提高。

Description

一种共挤SPC发泡地板及其制造方法 技术领域
本发明涉及一种发泡地板，尤其是SPC发泡地板及其制造方法。
 背景技术
随着PVC地板行业的不断发展，已渐渐成为实木地板、瓷砖、强化地板等传统铺地建材的替代材料，业内专家预计未来几年，塑胶地板就会被中国老百姓接受，成为家庭装修的常用地板装饰材料。房地产的高速发展，对于高层民用家装、商用装修，地面材料对楼层承重成为了一个新的要求，同时也对PVC地板产品提出了更高的要求。
 技术问题
传统SPC石塑地板密度1900 ~2000kg/m 3。由于SPC地板密度大，造成装饰过程中单位面积重量变大，而且还会增加运输成本。
技术解决方案
本发明要解决上述问题，从而提供一种SPC发泡地板。该地板相比传统SPC地板重量减轻约20~30%。并且在尺寸稳定性上表现更优。
本发明解决上述问题的技术方案如下：
一种SPC发泡地板，包括石塑基材结构，所述石塑基材结构从上到下依次包括第一稳定层、发泡层和第二稳定层；第一稳定层和第二稳定层均为以PVC树脂和填料粉为主要成分的片材；其中PVC树脂的质量份为100，填料粉的质量份为200~300；所述SPC发泡地板的密度为1.4~1.6g/cm 3。
作为上述技术方案的优选，所述第一稳定层的厚度为1~5mm；发泡层的厚度为2~10mm；第二稳定层的厚度为1~5mm。
作为上述技术方案的优选，所述填料粉为碳酸钙或以碳酸钙为主并含有碳酸氢钙、玻纤、碳纤中的一种或其任意组合的混合物。
作为上述技术方案的优选，所述第一稳定层和第二稳定层中还包括添加剂，所述添加剂选自钙锌稳定剂、内润滑剂、聚乙烯蜡、氯化聚乙烯、丙烯酸酯、复合润滑剂、着色剂中一种或其任意组合。
作为上述技术方案的进一步优选，当所述发泡层为化学发泡层时，所述第一稳定层和第二稳定层包括以下质量份的组分：聚氯乙烯树脂粉100、碳酸钙200~300、钙锌稳定剂4~7、内润滑剂0.8~1.3、聚乙烯蜡0.8~1.5、氯化聚乙烯4~6、丙烯酸酯2~5、复合润滑剂1.0~1.5、着色剂0.4~0.6。
作为上述技术方案另一种进一步的优选，当所述发泡层为物理发泡层时，所述第一稳定层和第二稳定层包括以下质量份的组分：聚氯乙烯树脂粉100、碳酸钙250~270、钙锌稳定剂5~6、内润滑剂1.0~1.2、聚乙烯蜡1.3~1.5、氯化聚乙烯5~6、丙烯酸酯2~3、复合润滑剂1.1~1.3、着色剂0.4~0.5。
润滑剂可以分为内润滑和外润滑两种。外润滑剂的主要作用是改善聚合物熔体与加工设备的热金属表面的摩擦。它与聚合物相容性较差，容易从熔体往外迁移，所以能在塑料熔体与金属的交界面形成润滑的薄层。内润滑剂与聚合物有良好的相容性，它在聚合物内部起到降低聚合物分子间内聚力的作用，从而改善塑料熔体的内摩擦生热和熔体的流动性。由于外润滑剂容易从熔体往外迁移的特性，使得塑料熔体在成型后易于跟模具脱离，故也常常把外润滑剂叫做脱模剂。但内润滑剂和外润滑剂并不是绝对的。会根据熔体的性质发生转变。如常见的润滑剂聚乙烯蜡和硬脂酸；当用于聚乙烯树脂时，聚乙烯蜡相容性较好，留在树脂内部作内润滑剂；当用于聚氯乙烯树脂时，硬脂酸相容性较好，留在树脂内部作内润滑剂，聚乙烯蜡相容性较差，迁移出树脂外部做外润滑剂。
而复合润滑剂，通常是指多元醇脂类。如辛酸、癸酸、月桂酸、棕榈酸、油酸、硬脂酸、花生酸、巳二酸、癸二酸等，由它们通过酯化、醇解、酯交换组成的多元醇脂类或经过多次酯化组成和复合组成的高分子复合醇酯产品的润滑剂。在这类润滑剂中，多元醇酯类的产品都是多元醇的部分酯化，在酯类中尚有未反应的羟基存在。极性的羟基基团常赋予制品良好的抗静电作用。因此，这些润滑剂也是PVC加工中的抗静电剂。季戊四醇脂肪酸酯是一种含有单、双、叁、肆酯的混合物，在PVC加工中，有良好的内润滑作用。这类产品由于反应程度的不同，随着羟基数的增加，其内润滑作用就会向外润滑剂转移。
作为上述技术方案的优选，所述发泡层为化学发泡层，包含以下质量份的组分：聚氯乙烯树脂粉100、碳酸钙150~200、钙锌稳定剂4~7、发泡剂0.6~1.2、聚乙烯蜡0.5~0.9、氯化聚氯乙烯2~3、丙烯酸酯2~3、润滑剂0.3~0.8、发泡调节剂6~9。
作为上述技术方案的进一步优选，所述发泡层包含着色剂时，着色剂的添加量为0.4~0.6。
作为上述技术方案的另一种优选，所述发泡层为物理发泡层，包含以下质量份的组分：聚氯乙烯树脂粉100、碳酸钙300~330、钙锌稳定剂4~7、内润滑剂1~1.5、聚乙烯蜡1~1.5、氯化聚乙烯4~8、丙烯酸酯3~5、复合润滑剂0.7~1.2。
作为上述技术方案的进一步优选，所述发泡层包含着色剂时，着色剂的添加量为0.4~0.6。
作为上述技术方案的优选，所述SPC发泡地板还包括装饰保护结构，所述装饰保护结构从上到下依次包括UV涂层、耐磨层和装饰层。
作为上述技术方案的优选，所述UV涂层的厚度为30~150μm；所述耐磨层为0.1mm~1.0mm厚的聚合物层。
作为上述技术方案的优选，所述耐磨层为以PVC树脂或乙烯基树脂为主要成分，添加适量的增塑剂、润滑剂、稳定剂经吹塑、压延或拉伸工艺制成。
作为上述技术方案的优选，所述装饰层为表面有花纹或图案的PVC薄膜。
本发明的另一个目的是提供一种SPC发泡地板的制备方法。
该法包括以下步骤：
a、将上下第一稳定层和第二稳定层的原料投入高速搅拌机进行混料升温，再经低速搅拌降温，然后经A挤出机挤出；
b、将发泡层的原料投入高速搅拌机进行混料升温，再经低速搅拌降温，然后进入B挤出机；若为化学发泡，原料经B挤出机均匀的熔融塑化，挤出；若为物理发泡，原料经B挤出机均匀的熔融塑化，同时往发泡剂注入装置注入4~10wt%高压液化的CO 2，维持模腔高压使CO 2继续以液态存在，使之与物料充分混合，在挤出过程中，进行泄压；
c、A挤出机的挤出物料进入模具流道分配器与B挤出机挤出的物料在模头处汇合，再经模头的模口共挤挤出，由此形成石塑基材结构；
d、模具出板经过底纹辊与第一镜面辊之间压制底纹，并将石塑基材结构输送至第二镜面辊与压纹辊之间；与此同时，耐磨层伺服喂膜辊和装饰层伺服喂膜辊分别将耐磨层和装饰层传送至第二镜面辊与排气辊之间进行预贴合；由此通过第二镜面辊与压纹辊的配合，将耐磨层和装饰纸压覆在基材层之上形成耐磨层和装饰层，并形成凹凸立体效果的面纹。
 有益效果
综上所述，本发明具有以下有益效果：
本发明通过在两个稳定层之间设置发泡层，显著地降低了地板的整体密度，达到1.4~1.6 g/m 3，由于发泡层设置在内部，并不影响整体地板的表强，同时提高了地板吸音性能；此外，试验证明本发明在尺寸稳定性上还得到了显著的提高。
附图说明
图1是本发明的结构示意图；
图2是本发明最佳实施例的设备示意图；
图2是本发明实施例一的设备示意图；
图中，1-UV涂层，2-耐磨层，3-装饰层，4-第一稳定层，5-发泡层，6-第二稳定层；10-底纹辊，20-第一镜面辊，30-第二镜面辊，40-压纹辊；200-耐磨层伺服喂膜辊，300-装饰层伺服喂膜辊，400-排气辊。
 本发明的最佳实施方式
如图1所示，一种共挤SPC发泡地板，包括装饰保护结构和石塑基材结构。
装饰保护结构从上到下依次包括UV涂层1、耐磨层2和装饰层3；石塑基材结构从上到下依次包括第一稳定层4、发泡层5和第二稳定层6。该SPC发泡地板的密度为1.531g/cm 3。
本实施例中，UV涂层1的厚度为100μm。
耐磨层2以PVC树脂为主要成分，添加适量的增塑剂、润滑剂、稳定剂经压延工艺制成。厚度为0.3mm。
装饰层3为表面有花纹的PVC薄膜。厚度为0.07mm。
第一稳定层4和第二稳定层6均为以PVC树脂和填料粉为主要成分的片材；其中PVC树脂的质量份为100份，填料粉为碳酸钙，其质量份为250份，还添加有添加剂，添加剂包含以下质量份的组分：
钙锌稳定剂      5
内润滑剂        1.0
聚乙烯蜡        1.4
氯化聚乙烯      5
丙烯酸酯        2
复合润滑剂      1.1
着色剂          0.5
上述助剂均为本领域的常规助剂，故不再赘述。
发泡层5为化学发泡层，包含以下质量份的组份：
PVC树脂粉        100
碳酸钙            160
钙锌稳定剂        6
发泡剂            0.8
聚乙烯蜡          0.6
氯化聚氯乙烯      2
丙烯酸酯          2
润滑剂            0.5
发泡调节剂        7
着色剂           0.5
上述助剂均为本领域的常规助剂，故不再赘述。
如图2所示，本实施例SPC发泡地板的制备方法如下：
a、将上下第一稳定层4和第二稳定层6的原料投入高速搅拌机进行混料升温，再经低速搅拌机降温，然后经A挤出机挤出；
b、将发泡层5的原料投入高速搅拌机进行混料升温，再经低速搅拌降温，然后进入B挤出机，原料经B挤出机均匀的熔融塑化，挤出；
c、A挤出机的挤出物料进入模具流道分配器与B挤出机挤出的物料在模头处汇合，再经模头的模口共挤挤出，由此形成石塑基材结构；
d、模具出板经过底纹辊10与第一镜面辊20之间压制底纹，并将石塑基材结构输送至第二镜面辊30与压纹辊40之间；与此同时，耐磨层伺服喂膜辊200和装饰层伺服喂膜辊300分别将耐磨层和装饰纸传送至第二镜面辊30与排气辊400之间进行预贴合；由此通过第二镜面辊30与压纹辊40的配合，将耐磨层和装饰纸压覆在基材层之上形成耐磨层和装饰层，并在正面形成凹凸立体效果的面纹。
最佳实施例与常规石塑地板（未发泡）的性能检测对比如下表所示
Figure 74272dest_path_image001
本发明的实施方式
如图1所示，一种共挤SPC发泡地板，包括装饰保护结构和石塑基材结构。
装饰保护结构从上到下依次包括UV涂层1、耐磨层2和装饰层3；石塑基材结构从上到下依次包括第一稳定层4、发泡层5和第二稳定层6。该SPC发泡地板的密度为1.465g/cm3。
本实施例中，UV涂层1的厚度为100μm。
耐磨层2以PVC树脂为主要成分，添加适量的增塑剂、润滑剂、稳定剂经压延工艺制成。厚度为0.3mm。
装饰层3为表面有花纹的PVC薄膜。厚度为0.07mm。
第一稳定层4和第二稳定层6均为以PVC树脂和填料粉为主要成分的片材；其中PVC树脂的质量份为100份，填料粉为碳酸钙，其质量份为250份，还添加有添加剂，添加剂包含以下质量份的组分：
钙锌稳定剂      5
内润滑剂        1.0
聚乙烯蜡        1.4
氯化聚乙烯      5
丙烯酸酯        2
复合润滑剂      1.1
着色剂          0.5
上述助剂均为本领域的常规助剂，故不再赘述。
发泡层5为物理发泡层，包含以下质量份的组份：
聚氯乙烯树脂粉      100
碳酸钙              330
钙锌稳定剂          5.5
内润滑剂            1.2
聚乙烯蜡            1
氯化聚乙烯          5.5
丙烯酸酯            3
复合润滑剂          1.0
上述助剂均为本领域的常规助剂，故不再赘述。
如图3所示，本实施例共挤SPC发泡地板的制备方法如下：
a、将上下第一稳定层4和第二稳定层6的原料投入高速搅拌机进行混料升温，再经低速搅拌降温，然后经A挤出机挤出；
b、将发泡层5的原料投入高速搅拌机，然后进入B挤出机进行混料升温，再经低速搅拌降温；原料经B挤出机均匀的熔融塑化，同时往发泡剂注入装置注入6wt%高压液化的CO2，维持模腔高压使CO2继续以液态存在，使之与物料充分混合，在挤出过程中，进行泄压；
c、A挤出机的挤出物料进入模具流道分配器与B挤出机挤出的物料在模头处汇合，再经模头的模口共挤挤出，由此形成石塑基材结构；
d、模具出板经过底纹辊10与第一镜面辊20之间压制底纹，并将石塑基材结构输送至第二镜面辊30与压纹辊40之间；与此同时，耐磨层伺服喂膜辊200和装饰层伺服喂膜辊300分别将耐磨层和装饰纸传送至第二镜面辊30与排气辊400之间进行预贴合；由此通过第二镜面辊30与压纹辊40的配合，将耐磨层和装饰纸压覆在基材层之上形成耐磨层和装饰层，并在正面形成凹凸立体效果的面纹。

Claims (10)

  1. 一种共挤SPC发泡地板，包括石塑基材结构，其特征在于：所述石塑基材结构从上到下依次包括第一稳定层（4）、发泡层（5）和第二稳定层（6）；第一稳定层（4）和第二稳定层（6）均为以PVC树脂和填料粉为主要成分的片材；其中PVC树脂的质量份为100，填料粉的质量份为200~300；所述SPC发泡地板的密度为1.4~1.6g/cm 3。
  2. 根据权利要求1所述的一种共挤SPC发泡地板，其特征在于：所述第一稳定层（4）的厚度为1~5mm；发泡层（5）的厚度为2~10mm；第二稳定层（6）的厚度为1~5mm。
  3. 根据权利要求1所述的一种共挤SPC发泡地板，其特征在于：所述填料粉为碳酸钙或以碳酸钙为主并含有碳酸轻钙、玻纤、碳纤中的一种或其任意组合的混合物。
  4. 根据权利要求1所述的一种共挤SPC发泡地板，其特征在于：所述第一稳定层（4）和第二稳定层（6）中还包括添加剂，所述添加剂选自钙锌稳定剂、内润滑剂、聚乙烯蜡、氯化聚乙烯、丙烯酸酯、复合润滑剂、着色剂中一种或其任意组合。
  5. 根据权利要求1所述的一种共挤SPC发泡地板，其特征在于，所述发泡层（5）为化学发泡层，包含以下质量份的组分：聚氯乙烯树脂粉100、碳酸钙150~200、钙锌稳定剂4~7、发泡剂0.6~1.2、聚乙烯蜡0.5~0.9、氯化聚氯乙烯 2~3、丙烯酸酯2~3、润滑剂0.3~0.8、发泡调节剂6~9。
  6. 根据权利要求5所述的一种共挤SPC发泡地板，其特征在于：所述发泡层（5）包含着色剂时，着色剂的添加量为0.3-0.5。
  7. 根据权利要求1所述的一种SPC发泡地板，其特征在于，所述发泡层（5）为物理发泡层，包含以下质量份的组分：聚氯乙烯树脂粉100、碳酸钙300~330、钙锌稳定剂4~7、内润滑剂1~1.5、聚乙烯蜡1~1.5、氯化聚乙烯4~8、丙烯酸酯3~5、复合润滑剂0.7~1.2。
  8. 根据权利要求7所述的一种共挤SPC发泡地板，其特征在于：所述发泡层（5）包含着色剂时，着色剂的添加量为0.4-0.6。
  9. 根据权利要求1所述的一种共挤SPC发泡地板，其特征在于：所述SPC发泡地板还包括装饰保护结构，所述装饰保护结构从上到下依次包括UV涂层（1）、耐磨层（2）和装饰层（3）。
  10. 根据权利要求9所述的一种共挤SPC发泡地板的制备方法，包括以下步骤：
    a、将上下第一稳定层（4）和第二稳定层（6）的原料投入高速搅拌机进行混料升温，经低速搅拌机降温，然后经A挤出机挤出；
    b、将发泡层（5）的原料投入高速搅拌机进行混料升温，经低速搅拌机降温，然后进入B挤出机；若为化学发泡，原料经B挤出机均匀的熔融塑化，挤出；若为物理发泡，原料经B挤出机均匀的熔融塑化，同时往发泡剂注入装置注入4~10wt%高压液化的CO 2，维持模腔高压使CO 2继续以液态存在，使之与物料充分混合，在挤出过程中，进行泄压；
    c、A挤出机的挤出物料进入模具流道分配器与B挤出机挤出的物料在模头处汇合，再经模头的模口共挤挤出，由此形成石塑基材结构；
    d、模具出板经过底纹辊（10）与第一镜面辊（20）之间压制底纹，并将石塑基材结构输送至第二镜面辊（30）与压纹辊（40）之间；与此同时，耐磨层伺服喂膜辊（200）和装饰层伺服喂膜辊（300）分别将耐磨层和装饰纸传送至第二镜面辊（30）与排气辊（400）之间进行预贴合；由此通过第二镜面辊（30）与压纹辊（40）的配合，将耐磨层和装饰纸压覆在基材层之上形成耐磨层和装饰层，并在正面形成凹凸立体效果的面纹。
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