WO2024017295A1 - 具有结皮的发泡板材及其制备方法 - Google Patents

具有结皮的发泡板材及其制备方法 Download PDF

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Publication number
WO2024017295A1
WO2024017295A1 PCT/CN2023/108149 CN2023108149W WO2024017295A1 WO 2024017295 A1 WO2024017295 A1 WO 2024017295A1 CN 2023108149 W CN2023108149 W CN 2023108149W WO 2024017295 A1 WO2024017295 A1 WO 2024017295A1
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WIPO (PCT)
Prior art keywords
layer
foam
base material
soft
wear
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PCT/CN2023/108149
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English (en)
French (fr)
Inventor
赵培东
张强
Original Assignee
安徽优胜美新材料科技有限公司
赵培东
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Publication of WO2024017295A1 publication Critical patent/WO2024017295A1/zh

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Classifications

    • 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
    • B32B33/00—Layered products characterised by particular properties or particular surface features, e.g. particular surface coatings; Layered products designed for particular purposes not covered by another single class
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C69/00—Combinations of shaping techniques not provided for in a single one of main groups B29C39/00 - B29C67/00, e.g. associations of moulding and joining techniques; Apparatus therefore
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/40—Layered products comprising a layer of synthetic resin comprising polyurethanes
    • 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
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • 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
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/32—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed at least two layers being foamed and next to each other
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/10—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials
    • E04F15/105—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials of organic plastics with or without reinforcements or filling materials
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/10—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials
    • E04F15/107—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials composed of several layers, e.g. sandwich panels
    • 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
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/0264—Polyester
    • 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

Definitions

  • the invention belongs to the technical field of decorative boards, and specifically relates to a foam board with crust and a preparation method thereof.
  • PVC foam board also known as Chevron board and Andy board
  • PVC foam board is divided into two types: crust foaming and free foaming.
  • PVC foam board is very widely used. Because of its relatively low price and superior performance, it is increasingly popular among the public. According to the production process, PVC foam board can be divided into PVC co-extruded foam board, PVC crusted foam board and PVC free foam board. , among which the surface hardness of PVC crusted foam board is lower than that of PVC co-extruded foam board, and it is difficult to produce scratches. It is widely used in cabinets, decoration, etc.
  • the present invention aims to solve at least one of the technical problems existing in the above-mentioned prior art. To this end, the present invention proposes a foam board with crust and a preparation method thereof.
  • a foam board with a crust includes a foam base material layer.
  • the lower surface of the foam base material layer is a crust layer, and the upper surface is formed from bottom to bottom.
  • the foamed thickening layer when the auxiliary functional layer includes a foamed thickening layer and the foamed thickening layer is directly in contact with the upper surface of the foamed base material layer, the foamed thickening layer The density of the layer is greater than the density of the foamed substrate layer.
  • the foam base material layer is PET foam material
  • the foam thickening layer is soft PETG foam material
  • the color film is compositely printed on it.
  • a wear-resistant layer, and the resulting board can be used as a floor mat, which has the advantages of being quiet, anti-noise, and increasing foot feel.
  • the density of the foamed thickened layer is 1.3 to 2.0 g/cm 3 .
  • the foam thickening layer must meet the standards of residual dent test and falling ball test.
  • the density of the foamed substrate layer is 0.7g/cm 3 to 1.8g/cm 3 .
  • the foam base material layer needs to be easy to form a skin.
  • the soft and hard filling layer is a soft thermoplastic material or a hard thermoplastic material that does not contain a foaming agent.
  • the degree of softness and hardness of the soft and hard filling layer material is controlled by adding a plasticizer.
  • adding more plasticizer can obtain a soft material, and adding less or no plasticizer can obtain a hard material.
  • the soft and hard filling layer can provide floor comfort by controlling its softness and hardness. This layer can be produced using an extruder co-extrusion method or a multi-layer lamination method.
  • the soft and hard filling layer is placed directly under the color film, its main function is to increase the comfort of the foot. At this time, the residual dent standard must be met; when the soft and hard filling layer is placed under the foamed thickening layer, its main function is to increase the foot comfort. is to increase thickness.
  • the foamed base material layer is made of raw materials including thermoplastic polymers and inorganic fillers, and the mass ratio of the thermoplastic polymers and inorganic fillers is 1: (1-4.5).
  • the thermoplastic polymer is one or more of PVC, PP, PET, PETG or PE.
  • a polyurethane (PUR) layer or a UV paint layer is further provided above the wear-resistant layer.
  • PUR layer or UV paint layer can improve scratch and wear resistance.
  • the UV paint layer undergoes surface treatment, and the surface treatment includes at least one of molding, excimer lamp matte treatment, and EB irradiation treatment.
  • the matte degree of the surface of the plate after the excimer lamp matte treatment is 0 to 3 degrees.
  • the foam board is installed by glue paving or locking assembly.
  • the present invention also provides a method for preparing the foamed board, which can be prepared by selecting one of the following methods according to requirements:
  • Method 1 Single-extrusion foam base material layer, the bottom is cooled to form a crust, and while hot, the color film layer and wear-resistant layer are compositely printed on the upper surface of the foam base material layer;
  • Method 2 The lower layer is a foam base material layer, and the upper layer is a foam thickening layer or soft and hard filling layer.
  • the upper and lower layers are extruded by co-extrusion, and then the bottom of the foam base material layer is cooled to form a crust.
  • the color film layer and the wear-resistant layer are sequentially compositely printed;
  • Method 3 Single extrusion foam base material layer. After the thickness of the foam base material layer is determined, the foam thickening layer or soft and hard filling layer is attached to it, and then the foam thickening layer or soft and hard filling layer is placed on top of it.
  • the upper surface is compositely printed with a color film layer and a wear-resistant layer in sequence, during which the bottom of the foam base material layer is cooled to form a crust;
  • Method 4 The lower layer is a foam base material layer, the middle layer is a foam thickening layer, and the upper layer is a soft and hard filling layer, or the middle layer is a soft and hard filling layer, the upper layer is a foaming thickening layer, and the upper, middle and lower layers are co-extruded. extrusion method, and then the bottom of the foamed base material layer is cooled to form a crust, and the color film layer and wear-resistant layer are sequentially printed on the upper surface of the upper layer;
  • the composite method of the printed color film layer can be any of the following: (1) directly laminating the printed color film with a pattern; (2) laminating the white film first, and then printing the pattern on the white film.
  • the cooling adopts a cooling roller
  • the cooling roller is a flat roller or a roller engraved with patterns and textures.
  • the textured cooling rollers during the crusting process can give the crust layer a structure similar to reinforcing ribs, further enhancing the anti-warping effect and improving the flatness of the board.
  • the composite method of the wear-resistant layer can be any of the following: (1) Directly bonding the wear-resistant film material; (2) Coating UV paint on the printed color film layer, and then Surface treatment to form a wear-resistant layer. Further, the surface treatment is embossing treatment.
  • embossing treatment is performed after the wear-resistant layer is compounded.
  • the extrusion uses a conical twin-screw extruder or a parallel twin-screw extruder; the co-extrusion uses a co-extrusion distributor or a co-extrusion die.
  • a structure of more than four rollers is configured behind the extrusion system.
  • the first group is a fixed thickness roller.
  • a pre-pasting mechanism is used behind the fixed thickness roller to directly attach the printed color film and wear-resistant layer to the foam base.
  • the material layers are compounded and embossed, or a multi-layer laminating system is used, using the first set of rollers as the thickness roller, the second set of rollers to fit the foamed thickening layer or the soft and hard filling layer, and the third set of rollers to
  • the fourth set of rollers is used to laminate the wear-resistant layer and then perform embossing treatment.
  • the bottom crust can be processed by any set of rollers after the fixed thickness roller. Among them, the second set of rollers is used for lamination.
  • the foam thickening layer or soft and hard filling layer is produced directly in roll material or using another set of extruders.
  • the bottom is cooled for crusting treatment.
  • the heat of the foam base material itself is used to directly attach the printed color film and wear-resistant layer to its upper surface.
  • Its anti-warping effect is the same as that of traditional The anti-warping effect of crusting on the upper and lower surfaces is equivalent, and the process of the present invention is simpler, no glue is needed, and the cost is lower; on this basis, a layer of foaming layer can also be co-extruded on the upper surface of the foam base material according to needs Or the combination of soft and hard filling layer or co-extruded foam layer and soft and hard filling layer, and then laminating the printed color film can also achieve the anti-warping effect.
  • the main functions of the foam thickening layer and the soft and hard filling layer are to increase the thickness of the board or/and For foot comfort, soft or hard foam thickening layers or soft and hard filling layers can be selected according to specific usage scenarios and performance requirements.
  • Figure 1 is a schematic structural diagram of a foam plate in Embodiment 1 of the present invention.
  • Figure 2 is a schematic structural diagram of the foam plate in Embodiment 2 of the present invention.
  • Figure 3 is a schematic structural diagram of the foam plate in Embodiment 3 of the present invention.
  • Figure 4 is a schematic structural diagram of the foam plate in Embodiment 4 of the present invention.
  • Figure 5 is a schematic structural diagram of the foam plate in Embodiment 5 of the present invention.
  • foam base material layer 100 soft and hard filling layer 200, foam thickening layer 300, printed color film layer 400, wear-resistant layer 500, crust 600.
  • This embodiment prepares a foam board with a crust.
  • a foam board with a crust.
  • it consists of a foam base material layer, a printed color film layer and a wear-resistant layer.
  • the lower surface of the foam base material layer is Crust layer, the specific preparation process is:
  • the extruder is used to single-extrude the foamed base material.
  • the temperature of the base material after extrusion is 190°C.
  • the bottom of the foamed base material passes through a 40°C cooling roller to form a crust, and is passed through the laminating mechanism.
  • Heat is used to sequentially composite and print the color film layer and the wear-resistant layer on the upper surface of the foam base material layer.
  • the formula of the foamed base material layer is shown in Table 1, and the density of the foamed base material layer is 1.7g/cm 3 .
  • This embodiment prepares a foam board with a crust. Refer to Figure 2. From bottom to top, it consists of a foam base material layer, a foam thickening layer, a printed color film layer and a wear-resistant layer. The specific preparation process for:
  • the foam base material layer and the foam thickening layer are co-extruded using a co-extrusion distributor.
  • the lower layer is the foam base material layer and the upper layer is the foam thickening layer.
  • the bottom of the foam base material is It is cooled to form a crust, and the color film layer and wear-resistant layer are sequentially printed on the upper surface of the foamed thickened layer through a laminating mechanism.
  • the formulas of the foamed base material layer and the foamed thickened layer are shown in Table 2.
  • the density of the foamed base material layer is 0.8g/cm 3 and the density of the foamed thickened layer is 1.5g/cm 3 .
  • the characteristics of the board in this embodiment are thickening and cost reduction, and it is suitable for household floors that have certain thickness requirements.
  • This embodiment prepares a foam board with a crust.
  • a foam board with a crust.
  • it consists of a foam base material layer, a soft and hard filling layer, a printed color film layer and a wear-resistant layer.
  • the specific preparation process is as follows :
  • the foam base material layer and the soft and hard filling layer are co-extruded using a co-extrusion distributor.
  • the lower layer is the foam base material layer and the upper layer is the soft and hard filling layer.
  • the bottom of the foam base material is cooled to form It is in the form of a crust, and the printed color film layer and wear-resistant layer are sequentially compounded on the upper surface of the soft and hard filling layer through a laminating mechanism.
  • the formulas of the foamed base material layer and the soft and hard filling layer are shown in Table 3.
  • the density of the foamed base material layer is 1.2g/cm 3 .
  • the characteristics of the board in this embodiment are heat resistance, good flatness, good foot feel, and good comfort. It is suitable for indoor scenes with floor-to-ceiling windows or places with large fluctuations in hot and cold temperature differences. It is suitable for large-area paving and has good stability.
  • This embodiment prepares a foam board with a crust.
  • a foam board with a crust.
  • it consists of a foam base material layer, a foam thickening layer, a soft and hard filling layer, a printed color film layer and a wear-resistant layer. layer, the specific preparation process is:
  • the lower layer is the foam base material layer
  • the middle layer is the foam thickening layer
  • the upper layer is the soft and hard filling layer.
  • the characteristics of the board of this embodiment are heat resistance, good flatness, and more comfortable foot feel compared to Embodiment 3. It is suitable for home use, commercial use, or places where the temperature difference between hot and cold fluctuates greatly. It can also be used in geothermal systems and is suitable for large areas. Paving, good stability.
  • This embodiment prepares a foam board with a crust.
  • a foam board with a crust.
  • it consists of a foam base material layer, a soft and hard filling layer, a foam thickening layer, a printed color film layer and a wear-resistant layer. layer, the specific preparation process is:
  • a co-extrusion distributor is used to co-extrude the foam base material layer, soft and hard filling layer and foam thickening layer.
  • the lower layer is the foam base material layer
  • the middle layer is the soft and hard filling layer
  • the upper layer is the foam thickening layer.
  • the bottom of the foam base material layer is cooled to form a crust, and the color film layer and the wear-resistant layer are sequentially printed on the upper surface of the foam thickened layer through a laminating mechanism.
  • the formulas of the foam base material layer, soft and hard filling layer, and foam thickening layer are shown in Table 5.
  • the densities of the foam base material layer and the foam thickening layer are both 1.3g/cm 3 .
  • the characteristic of the board of this embodiment is that it feels more silent under the feet than that of Embodiment 4. It is suitable for industrial and commercial use and places where the temperature difference between hot and cold fluctuates greatly. It can be paved over a large area and can be installed with floor heating.
  • a lightweight SPC base material was prepared in this comparative example.
  • the difference from Example 1 is that the upper and lower sides of the base material are crusted.
  • the specific process is:
  • the SPC base material is extruded by a single extruder.
  • the temperature of the base material after extrusion is 190°C.
  • This comparative example prepares a WPC board.
  • the difference from Example 1 is that the base material is a WPC base material, and the upper and lower sides of the base material are crusted.
  • the specific process is:
  • the WPC base material is extruded by a single extruder.
  • the temperature of the base material after extrusion is 180°C.
  • the surface and bottom of the foam base material pass through a 40°C cooling roller to form a crust, and then glue is applied to the base material.
  • the upper surface of the material is adhered to the printed color film layer and wear-resistant layer in sequence.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Laminated Bodies (AREA)
  • Extrusion Moulding Of Plastics Or The Like (AREA)

Abstract

本发明公开了一种具有结皮的发泡板材及其制备方法，发泡板材包括发泡基材层，发泡基材层的下表面为结皮层，上表面自下而上依次为印刷彩膜层和耐磨层；或者，发泡基材层的上表面自下而上依次为辅助功能层、印刷彩膜层和耐磨层，辅助功能层包括发泡增厚层和软硬填充层中的一种或两种组合。本发明的发泡基材挤出后，底部经冷却做结皮处理，同时利用发泡基材本身的热量在其上表面直接贴合印刷彩膜和耐磨层，其防翘曲效果与传统上下表面做结皮的防翘曲效果相当，且本发明工艺更简单，无需使用胶水，成本更低。

Description

具有结皮的发泡板材及其制备方法 技术领域
本发明属于装饰板材技术领域，具体涉及一种具有结皮的发泡板材及其制备方法。
背景技术
PVC发泡板又称为雪弗板和安迪板，分为结皮发泡和自由发泡两种。PVC发泡板用途非常广泛，因其价格相对低性能优越，日益受到大众欢迎，按制作工艺PVC发泡板可分为PVC共挤发泡板、PVC结皮发泡板和PVC自由发泡板，其中PVC结皮发泡板表面硬度低于PVC共挤发泡板，难产生划痕，广泛应用于橱柜、装饰等。目前的PVC结皮发泡板都是挤出发泡基材后在基材上下表面做结皮处理，维持上下表面的收缩平衡，防止基材发生翘曲变形，但此法在基材上表面做完冷却结皮处理后，需要用胶水将印刷彩膜和耐磨层贴到基材表面，其制作工序繁杂，胶水使用量多，增加成本。
发明内容
本发明旨在至少解决上述现有技术中存在的技术问题之一。为此，本发明提出一种具有结皮的发泡板材及其制备方法。
根据本发明的一个方面，提出了一种具有结皮的发泡板材，所述发泡板材包括发泡基材层，所述发泡基材层的下表面为结皮层，上表面自下而上依次为印刷彩膜层和耐磨层；或者，所述发泡基材层的上表面自下而上依次为辅助功能层、印刷彩膜层和耐磨层，所述辅助功能层包括发泡增厚层和软硬填充层中的一种或两种组合。
在本发明的一些实施方式中，当所述辅助功能层包括发泡增厚层且所述发泡增厚层直接与所述发泡基材层的上表面接触时，所述发泡增厚层的密度大于所述发泡基材层的密度。根据性能需求选择合适的发泡基材层和发泡增厚层配方，如发泡基材层为PET发泡材料，发泡增厚层为软质的PETG发泡材料，上面复合印刷彩膜和耐磨层，所得板材可作为地垫，具有静音、抗噪、增加脚感的优点。
在本发明的一些优选的实施方式中，所述发泡增厚层的密度为1.3g/cm3至2.0g/cm3。发泡增厚层需符合残余凹陷测试及落球测试的标准。
在本发明的一些优选的实施方式中，所述发泡基材层的密度为0.7g/cm3至1.8g/cm3。发泡基材层需易于结皮。
在本发明的一些实施方式中，所述软硬填充层为不含发泡剂的软质热塑性材料或硬质热塑性材料。优选的，通过加入可塑剂控制软硬填充层材质的软硬程度，如加入较多可塑剂可获得软质材料，加入较少或不加可塑剂可获得硬质材料。软硬填充层可通过控制其软硬程度来提供地板脚感的舒适性，该层可使用挤出机共挤方式或使用多层贴合方式生产。当软硬填充层直接置于彩膜下方时，其作用主要是增加脚感舒适性，此时需达到残余凹陷度标准；当软硬填充层置于发泡增厚层下方时，其作用主要是增加厚度。
在本发明的一些实施方式中，所述发泡基材层由包括热塑性高分子和无机填料的原料制成，所述热塑性高分子和无机填料的质量比为1：(1-4.5)。优选的，所述热塑性高分子为PVC、PP、PET、PETG或PE中的一种或几种。
在本发明的一些实施方式中，所述耐磨层上方还设有聚氨酯(PUR)层或UV漆层。PUR层或UV漆层可提升耐刮耐磨性能。
在本发明的一些实施方式中，所述UV漆层经过表面处理，所述表面处理包括模压、准分子灯哑光处理和EB辐照处理中的至少一种。优选的，经所述准分子灯哑光处理后板材表面的哑光度为0至3度。
在本发明的一些实施方式中，所述发泡板材的安装方式为胶水铺装或以锁扣组装。
本发明还提供所述的发泡板材的制备方法，按需求选择以下其中一种方法制得：
方法一：单挤出发泡基材层，其底部经冷却形成结皮状，并趁热在发泡基材层的上表面依次复合印刷彩膜层和耐磨层；
方法二：下层为发泡基材层，上层为发泡增厚层或软硬填充层，上下两层以共挤的方式挤出，然后发泡基材层的底部经冷却形成结皮状，并在发泡增厚层或软硬填充层的上表面依次复合印刷彩膜层和耐磨层；
方法三：单挤出发泡基材层，发泡基材层经定厚后在其上方贴合发泡增厚层或软硬填充层，然后在发泡增厚层或软硬填充层的上表面依次复合印刷彩膜层和耐磨层，期间发泡基材层的底部经冷却形成结皮状；和
方法四：下层为发泡基材层、中层为发泡增厚层、上层为软硬填充层，或中层为软硬填充层、上层为发泡增厚层，上中下三层以共挤的方式挤出，然后发泡基材层的底部经冷却形成结皮状，并在上层的上表面依次复合印刷彩膜层和耐磨层；
其中，所述印刷彩膜层的复合方法可选以下任一种：(1)直接贴合带图案的印刷彩膜；(2)先贴合白膜，然后在白膜上打印图案。
在本发明的一些实施方式中，所述冷却采用冷却辊轮，所述冷却辊轮为平辊或雕刻有图案、纹路的辊轮。结皮处理过程中带有纹路的冷却辊轮可赋予结皮层类似加强筋的结构，进一步增强防翘曲效果，提高板材平整性。
在本发明的一些实施方式中，所述耐磨层的复合方法可选以下任一种：(1)直接贴合耐磨膜材；(2)在印刷彩膜层上涂布UV漆，再做表面处理形成耐磨层。进一步地，表面处理为压纹处理。
在本发明的一些实施方式中，在复合所述耐磨层后做压纹处理。
在本发明的一些实施方式中，所述挤出采用锥形双螺杆挤出机或平行双螺杆挤出机；所述共挤采用共挤分配器或共挤模头。
在本发明的一些实施方式中，挤出系统的后方配置四辊以上结构，第一组为定厚辊，定厚辊后方使用预贴机构，将印刷彩膜和耐磨层直接与发泡基材层复合并进行压纹处理，或使用多层贴合系统，以第一组辊轮作为定厚辊，第二组辊轮贴合发泡增厚层或软硬填充层，第三组辊轮做印刷彩膜贴合，第四组辊轮做耐磨层贴合后做压纹处理，底层结皮选择在定厚辊后任一组辊轮处理，其中第二组辊轮贴合的发泡增厚层或软硬填充层为卷材或使用另一组挤出机直接生产。
根据本发明的一种优选的实施方式，至少具有以下有益效果：
本发明的发泡基材挤出后，底部经冷却做结皮处理，同时利用发泡基材本身的热量在其上表面直接贴合印刷彩膜和耐磨层，其防翘曲效果与传统上下表面做结皮的防翘曲效果相当，且本发明工艺更简单，无需使用胶水，成本更低；在此基础上，还可以根据需求在发泡基材上表面共挤一层发泡层或软硬填充层或共挤发泡层和软硬填充层两层的组合，后贴合印刷彩膜，也能达到防翘曲效果。发泡增厚层和软硬填充层的主要作用都是增加板材厚度或/和增加 脚感舒适性，可根据具体的使用场景和性能需求选择软质或硬质的发泡增厚层或软硬填充层。
附图说明
下面结合附图和实施例对本发明做进一步的说明，其中：
图1为本发明实施例1发泡板材的结构简图；
图2为本发明实施例2发泡板材的结构简图；
图3为本发明实施例3发泡板材的结构简图；
图4为本发明实施例4发泡板材的结构简图；
图5为本发明实施例5发泡板材的结构简图。
附图标记：发泡基材层100、软硬填充层200、发泡增厚层300、印刷彩膜层400、耐磨层500、结皮600。
具体实施方式
以下将结合实施例对本发明的构思及产生的技术效果进行清楚、完整地描述，以充分地理解本发明的目的、特征和效果。显然，所描述的实施例只是本发明的一部分实施例，而不是全部实施例，基于本发明的实施例，本领域的技术人员在不付出创造性劳动的前提下所获得的其他实施例，均属于本发明保护的范围。
实施例1
本实施例制备了一种具有结皮的发泡板材，参照图1，其自下而上依次为发泡基材层、印刷彩膜层和耐磨层，发泡基材层的下表面为结皮层，具体制备过程为：
采用挤出机单挤出发泡基材，挤出后基材温度为190℃，经过定厚辊后，发泡基材的底部经过40℃冷却辊形成结皮状，并通过贴合机构趁热在发泡基材层的上表面依次复合印刷彩膜层和耐磨层。其中发泡基材层的配方如表1所示，发泡基材层的密度为1.7g/cm3。
表1

实施例2
本实施例制备了一种具有结皮的发泡板材，参照图2，其自下而上依次为发泡基材层、发泡增厚层、印刷彩膜层和耐磨层，具体制备过程为：
采用共挤分配器共挤出发泡基材层和发泡增厚层，其中下层为发泡基材层，上层为发泡增厚层，经过定厚辊后，发泡基材的底部经冷却形成结皮状，并通过贴合机构在发泡增厚层的上表面依次复合印刷彩膜层和耐磨层。其中发泡基材层和发泡增厚层的配方如表2所示，发泡基材层的密度为0.8g/cm3，发泡增厚层的密度是1.5g/cm3。本实施例板材的特点是增厚，降低成本，适用于对厚度有一定要求的家用地板。
表2
实施例3
本实施例制备了一种具有结皮的发泡板材，参照图3，其自下而上依次为发泡基材层、软硬填充层、印刷彩膜层和耐磨层，具体制备过程为：
采用共挤分配器共挤出发泡基材层和软硬填充层，其中下层为发泡基材层，上层为软硬填充层，经过定厚辊后，发泡基材的底部经冷却形成结皮状，并通过贴合机构在软硬填充层的上表面依次复合印刷彩膜层和耐磨层。其中发泡基材层和软硬填充层的配方如表3所示，发泡基材层的密度为1.2g/cm3。本实施例板材的特点是耐热，平整度佳，脚感好，舒适性佳，适用于带落地窗的室内场景，或冷热温差波动较大的场所，适合大面积铺装，稳定性佳。
表3
实施例4
本实施例制备了一种具有结皮的发泡板材，参照图4，其自下而上依次为发泡基材层、发泡增厚层、软硬填充层、印刷彩膜层和耐磨层，具体制备过程为：
采用共挤分配器共挤出发泡基材层、发泡增厚层和软硬填充层，其中下层为发泡基材层，中层为发泡增厚层，上层为软硬填充层，经过定厚辊后，发泡基材层的底部经冷却形成结皮状，并通过贴合机构在软硬填充层的上表面依次复合印刷彩膜层和耐磨层。其中发泡基材层、发泡增厚层和软硬填充层的配方如表4所示，发泡基材层的密度为1.1g/cm3，发泡增厚层的密度是1.4g/cm3。本实施例板材的特点是耐热，平整度佳，脚感对比实施例3更具舒适性，适合家用、商业用，或冷热温差波动较大的场所，还可用于地热系统，适合大面积铺装，稳定性佳。
表4

实施例5
本实施例制备了一种具有结皮的发泡板材，参照图5，其自下而上依次为发泡基材层、软硬填充层、发泡增厚层、印刷彩膜层和耐磨层，具体制备过程为：
采用共挤分配器共挤出发泡基材层、软硬填充层和发泡增厚层，其中下层为发泡基材层，中层为软硬填充层，上层为发泡增厚层，经过定厚辊后，发泡基材层的底部经冷却形成结皮状，并通过贴合机构在发泡增厚层的上表面依次复合印刷彩膜层和耐磨层。其中发泡基材层、软硬填充层和发泡增厚层的配方如表5所示，发泡基材层和发泡增厚层的密度均为1.3g/cm3。本实施例板材的特点是脚感对比实施例4更具静音效果，适合工商业使用，以及冷热温差波动较大的场所，可大面积铺装，可加装地热。
表5
对比例1
本对比例制备了一种轻质SPC基材，与实施例1的区别在于，基材的上下两面均做结皮，具体过程为：
采用挤出机单挤出SPC基材，挤出后基材温度为190℃，经过定厚辊后，基材的表面和底部经过40℃冷却辊形成结皮状。
对比例2
本对比例制备了一种WPC板，与实施例1的区别在于，基材为WPC基材，基材的上下两面均做结皮，具体过程为：
采用挤出机单挤出WPC基材，挤出后基材温度为180℃，经过定厚辊后，发泡基材的表面和底部经过40℃冷却辊形成结皮状，后用胶水在基材的上表面依次贴合印刷彩膜层和耐磨层。
表6性能测试
上面结合附图对本发明实施例作了详细说明，但是本发明不限于上述实施例，在所属技术领域普通技术人员所具备的知识范围内，还可以在不脱离本发明宗旨的前提下作出各种变化。此外，在不冲突的情况下，本发明的实施例及实施例中的特征可以相互组合。

Claims (10)

  1. 一种具有结皮的发泡板材，其特征在于，所述发泡板材包括发泡基材层，所述发泡基材层的下表面为结皮层，上表面自下而上依次为印刷彩膜层和耐磨层；或者，所述发泡基材层的上表面自下而上依次为辅助功能层、印刷彩膜层和耐磨层，所述辅助功能层包括发泡增厚层和软硬填充层中的一种或两种组合。
  2. 根据权利要求1所述的发泡板材，其特征在于，当所述辅助功能层包括发泡增厚层且所述发泡增厚层直接与所述发泡基材层的上表面接触时，所述发泡增厚层的密度大于所述发泡基材层的密度。
  3. 根据权利要求2所述的发泡板材，其特征在于，所述发泡增厚层的密度为1.3g/cm3至2.0g/cm3。
  4. 根据权利要求2所述的发泡板材，其特征在于，所述发泡基材层的密度为0.7g/cm3至1.8g/cm3。
  5. 根据权利要求1所述的发泡板材，其特征在于，所述软硬填充层为不含发泡剂的软质热塑性材料或硬质热塑性材料。
  6. 根据权利要求1所述的发泡板材，其特征在于，所述发泡基材层由包括热塑性高分子和无机填料的原料制成，所述热塑性高分子和无机填料的质量比为1：(1-4.5)。
  7. 根据权利要求1所述的发泡板材，其特征在于，所述耐磨层上方还设有PUR层或UV漆层。
  8. 根据权利要求7所述的发泡板材，其特征在于，所述UV漆层经过表面处理，所述表面处理包括模压、准分子灯哑光处理和EB辐照处理中的至少一种。
  9. 如权利要求1-8任一项所述的发泡板材的制备方法，其特征在于，选择以下一种方法：
    方法一包括：单挤出发泡基材层，其底部经冷却形成结皮状，并趁热在发泡基材层的上表面依次复合印刷彩膜层和耐磨层；
    方法二包括：下层为发泡基材层，上层为发泡增厚层或软硬填充层，上下两层以共挤的方式挤出，然后发泡基材层的底部经冷却形成结皮状，并在发泡增厚层或软硬填充层的上表面依次复合印刷彩膜层和耐磨层；
    方法三包括：单挤出发泡基材层，发泡基材层经定厚后在其上方贴合发泡增厚层或软硬填充层，然后在发泡增厚层或软硬填充层的上表面依次复合印刷彩膜层和耐磨层，期间发泡基材层的底部经冷却形成结皮状；和
    方法四包括：下层为发泡基材层、中层为发泡增厚层、上层为软硬填充层，或中层为软硬填充层、上层为发泡增厚层，上中下三层以共挤的方式挤出，然后发泡基材层的底部经冷却形成结皮状，并在上层的上表面依次复合印刷彩膜层和耐磨层；
    其中，可选地，所述印刷彩膜层的复合方法为以下任一种：(1)直接贴合带图案的印刷彩膜；和(2)先贴合白膜，然后在白膜上打印图案。
  10. 根据权利要求9所述的制备方法，其特征在于，所述冷却采用冷却辊轮，所述冷却辊轮为平辊或雕刻有图案、纹路的辊轮。
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JP2015174242A (ja) * 2014-03-13 2015-10-05 アキレス株式会社 装飾シート
CN205242950U (zh) * 2015-11-16 2016-05-18 方应龙 一种可定制的pvc地板
US20170144418A1 (en) * 2015-11-19 2017-05-25 Renhong CHEN Anti-slippery mat and method of manufacturing thereof
CN109483895A (zh) * 2018-12-14 2019-03-19 天津市天德橡塑机械股份有限公司 用于塑料发泡板材进行多层复合增厚的生产工艺及设备
CN115339210A (zh) * 2022-07-20 2022-11-15 安徽优胜美新材料科技有限公司 具有结皮的发泡板材及其制备方法

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