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CN110485674A - 复合地板及其制造工艺 - Google Patents

复合地板及其制造工艺 Download PDF

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Publication number
CN110485674A
CN110485674A CN201910864422.6A CN201910864422A CN110485674A CN 110485674 A CN110485674 A CN 110485674A CN 201910864422 A CN201910864422 A CN 201910864422A CN 110485674 A CN110485674 A CN 110485674A
Authority
CN
China
Prior art keywords
layer
composite floor
floor board
pvc
paper
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
CN201910864422.6A
Other languages
English (en)
Inventor
黎国平
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Jiangsu Langyue New Materials Technology Co Ltd
Original Assignee
Zhenjiang Langyue Plastic Industry Co Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Zhenjiang Langyue Plastic Industry Co Ltd filed Critical Zhenjiang Langyue Plastic Industry Co Ltd
Priority to CN201910864422.6A priority Critical patent/CN110485674A/zh
Publication of CN110485674A publication Critical patent/CN110485674A/zh
Priority to PCT/CN2020/114789 priority patent/WO2021047639A1/zh
Priority to US17/692,808 priority patent/US20220194068A1/en
Pending legal-status Critical Current

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Classifications

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    • B32B37/0015—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding involving treatment or provisions in order to avoid deformation or air inclusion, e.g. to improve surface quality to avoid warp or curl
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Abstract

本发明公开了一种复合地板，其技术方案要点是包括依次设置的耐磨层、PVC花纹面料层、基材层、平衡层、静音层，所述耐磨层为三聚氰胺耐磨纸层。该种复合地板花纹清晰灵动，且耐磨耐刮性远优于设置了PVC耐磨层的常规地板。同时，本发明还相应公开了一种复合地板制造工艺，其包括铺料、热压、脱模和回火步骤，不仅工艺步骤简单且制得的复合地板尺寸稳定性高、耐磨耐刮性能优异。

Description

复合地板及其制造工艺
技术领域
本发明涉及一种复合地板及其制造工艺。
背景技术
复合地板因兼具装饰性和远优于传统竹木材质地板的耐磨性、尺寸稳定性等优点，而广受欢迎。如申请公开号为CN104847082B的中国专利公开了一种阻燃PVC地板，包括基体层、位于基体层之上的装饰层及位于装饰层之上的耐磨层，所述基体层的材料包括PVC粉、阻燃剂及偶联剂，所述装饰层为经三聚氰胺处理的装饰纸，所述耐磨层的材料包括PVC粉和阻燃剂，且所述基体层和耐磨层中至少其中之一的材料包括消烟剂。装饰层选择三聚氰胺浸胶纸。
但是，PVC耐磨层的耐磨性仅属于中等水平，使得地板在使用过程中长时间的踩踏、摩擦、刮伤等容易造成地板表面粗糙，直接影响装饰层的装饰效果，使得装饰层的花纹或纹路模糊，清晰度差。
发明内容
针对现有技术存在的不足，本发明的目的在于提供一种复合地板，其具有耐磨性佳、装饰层花纹能长久保持清晰的优势。
为实现上述目的，本发明提供了如下技术方案：
一种复合地板，包括依次设置的耐磨层、PVC花纹面料层、基材层、平衡层、静音层，所述耐磨层为三聚氰胺耐磨纸层。
通过采用上述技术方案，至少具有如下有益效果：
本发明的复合地板选择耐磨性更好的三聚氰胺耐磨纸层代替PVC耐磨层，使得地板的耐磨性大幅提升。同时，以PVC花纹面料层代替了常规的三聚氰胺浸胶纸装饰层，使得装饰花纹或图案的清晰度和灵动性更佳。本发明的复合地板结构简单，但是耐磨性能优异，能长时间保持装饰花纹的清晰。平衡层的设置，使得复合地板整体尺寸稳定，不易变形或翘曲。吸音层则具有提升地板隔音降噪效果的作用。
进一步地，所述PVC花纹面料层的正面和/或反面设置有胶黏层。
通过采用上述技术方案，增加了PVC花纹面料层与相邻材料层之间的复合牢度，提升了复合地板的整体尺寸稳定性。
进一步地，所述胶黏层包括按重量份计的如下组分，
氯化橡胶 2-7份
过氯乙烯树脂 8-12份
改性低分子聚酰胺热熔胶 2-7份
高支化妥尔油树脂 2-7份
抗氧剂 0.5-1.5份
有机溶剂 60-90份。
上述具体配比的胶黏层粘结牢度高，且具有极佳的防水性能和粘结牢度，使得PVC花纹面料层与相邻材料层之间不易脱胶、开裂、鼓泡，对于提升复合地板的尺寸稳定性和耐磨性具有促进作用。
针叶树木用硫酸盐法制纸浆的蒸煮废液得到的浮渣，经酸化后得到的油状物是松香酸、油酸和亚油酸为主的混合物，称为妥尔油（tall oil）。妥尔油经分馏得到的妥尔油脂肪酸（Tall oil fatty acid），其中含6%～8%松香酸（Abietic acid），是制皂原料。再进一步分馏，可得到含树脂酸低于2%的高质量妥尔油脂肪酸。本申请中的高支化妥尔油树脂是指以妥尔油脂肪酸为原料经过超支化改性得到的产物，具体制备方法在WO0056802A1、WO03062306A1等专利申请文件中均有记载，此处不再赘述。
低分子聚酰胺热熔胶由脂肪酸的二聚体或三聚体与有机胺缩合而成，再在交联剂存在的前提下用脂肪族二元酸（HOOC-R-COOH，R表示烷基）进行接枝、交联改性制备而得。优选R为C2-C12的烷基二羧酸改性低分子聚酰胺热熔胶，制得的改性低分子聚酰胺热熔胶的韧性大幅提升。本发明的改性低分子聚酰胺热熔胶可以是自制改性热熔胶或市售改性热熔胶。
抗氧剂剂选择市售适合热熔胶的抗氧剂即可，如抗氧剂1726、抗氧剂801、抗氧剂808等。有机溶剂选择乙酸乙酯、乙酸丁酯、丁酮、丙酮等有机溶剂中的一种或多种均可。
进一步地，所述基材层分别选自SPC基材层、WPC基材层。
SPC基材具有轻薄、环保、耐磨、防火等优点；WPC基材具有环保、机械性能优异、尺寸稳定性佳的优势，两者均使得本发明的方案容易实现。
进一步地，所述静音层为软木层或EVA泡棉或IXPE泡棉。
通过采用上述技术方案，均具有提升复合地板吸音降噪能力的作用。
进一步地，所述PVC花纹面料层包括用水性PVC油墨或油性PVC油墨印制的花纹层。
通过采用上述技术方案，复合地板的装饰花纹清晰度高、灵动性高，装饰效果优于三聚氰胺浸胶装饰纸。
进一步地，所述平衡层为平衡纸层、三聚氰胺耐磨纸层、或PVC膜与三聚氰胺平衡纸层的结合。
通过采用上述技术方案，具有平衡复合地板表层和底层形变差异的作用，提升了复合地板尺寸稳定性和防潮防腐性能。
本发明的目的在于提供一种复合地板制造工艺，采用该工艺制造的复合地板具有防潮防腐蚀性好、尺寸稳定性高、使用耐久性佳的优势优势。
为实现上述目的，本发明提供了如下技术方案：
一种复合地板的制造工艺，包括如下步骤，
铺料：按照由下至上的顺序依次将静音层、平衡层、基材层、PVC花纹面料层、耐磨层铺设于层压设备的模具，所述耐磨层为三聚氰胺耐磨纸层；
热压：于130-150℃、5-21MPa条件下进行热压，热压时间控制在20-60min；
脱模：自然冷却至室温，脱模得复合地板；
回火：于80-100℃条件下对脱模得到的复合地板进行二次热压处理。
通过采用上述技术方案，工艺步骤简单，铺料完成后一次性热压即可成型。后续回火工序，对于复合地板尺寸稳定性的提升具有促进作用，极大提升了复合地板的使用性能。采用本发明工艺制得的复合地板具有尺寸稳定性高、耐磨性好的优势。
进一步地，所述回火工序在脱模得到的复合地板完全冷却后，并养生24h后再进行。
通过采用上述技术方案，对复合地板尺寸稳定性的提升效果更显著。
综上所述，本发明具有以下有益效果：
1、本发明的复合地板采用三聚氰胺耐磨纸层和PVC花纹面料层复合使用，不仅装饰花纹相较于常规的三聚氰胺装饰纸更清晰更灵动，且耐磨耐刮性相较于设置PVC耐磨层的地板大幅提升；
2、PVC花纹面料层的正面和/或发明设置特定组分配比的胶黏层，大幅提升了复合地板的复合牢度，且使得复合地板的耐磨性更佳；
3、平衡层和吸音层的设置，使得复合地板具有高尺寸稳定性和良好的吸音降噪效果；
4、本发明还公开了一种复合地板制造工艺，其具有工艺步骤简单，制得的复合地板尺寸稳定性高、耐磨耐刮性好。
附图说明
图1为实施例中复合地板的结构示意图；
图2为实施例中PVC面料层及胶黏层的结构示意图；
图3为实施例复合地板制造工艺的工艺流程图。
图中：1、耐磨层；2、PVC花纹面料层；21、胶黏层；22、花纹层；23、本体层；3、基材层；4、平衡层；5、静音层。
具体实施方式
以下结合附图对本发明作进一步详细说明。
实施例1：
一种复合地板，参照图1，其包括依次设置的耐磨层1、PVC花纹面料层2、基材层3、平衡层4和静音层5。其中，耐磨层1为三聚氰胺耐磨纸层；基材层3为SPC基材层；平衡层4为平衡纸层；静音层5为软木层。
参照图2，PVC花纹面料层2包括本体层23和由水性PVC油墨在本体层23的正面印刷形成的花纹层22。PVC花纹面料层2的正反两面均设置有胶黏层21。胶黏层21由按照如下配比配置的胶水涂覆而成：
氯化橡胶 5g
过氯乙烯树脂 10g
改性低分子聚酰胺热熔胶 5g
高支化妥尔油树脂 5g
抗氧剂1726 1g
乙酸丁酯 50g
丁酮 24g，
其中改性低分子聚酰胺热熔胶为丁二酸改性低分子聚酰胺热熔胶。
参照图3，本实施例的复合地板的制造工艺如下：
按照上述配方称取原料，加热熔融混合均匀得预处理用胶水。然后，将预处理用胶水均匀施加于PVC花纹面料层2表面，形成胶黏层21。
随后，按照由下至上的顺序依次将软木层、平衡纸层、SPC基材层、PVC花纹面料层2和三聚氰胺耐磨纸层铺设于多层热压设备的模具；于140℃、15MPa条件下进行热压，控制热压时间为30min。
完成热压后，自然冷却至室温，脱模得复合地板。将制得的复合地板于室温条件下养生24h后，进行回火。回火同样在多层热压设备上完成，回火温度为90℃、回火时间为15min。完成回火后出片，控制出片温度≤80℃，然后自然冷却至室温得成品复合地板。
实施例2：
一种复合地板，参照图1，其包括依次设置的耐磨层1、PVC花纹面料层2、基材层3、平衡层4和静音层5。其中，耐磨层1为三聚氰胺耐磨纸层；基材层3为SPC基材层；平衡层4为三聚氰胺耐磨纸层；静音层5为EVA泡棉层。
参照图2，PVC花纹面料层2包括本体层23和由水性PVC油墨在本体层23的正面印刷形成的花纹层22。PVC花纹面料层2的正反两面均设置有胶黏层21。胶黏层21由按照如下配比配置的胶水涂覆而成：
氯化橡胶 2g
过氯乙烯树脂 8g
改性低分子聚酰胺热熔胶 2g
高支化妥尔油树脂 2g
抗氧剂1726 0.5g
乙酸丁酯 40g
丁酮 20g。
其中改性低分子聚酰胺热熔胶为丁二酸改性低分子聚酰胺热熔胶。
参照图3，本实施例的复合地板的制造工艺如下：
按照上述配方称取原料，加热熔融混合均匀得预处理用胶水。然后，将预处理用胶水均匀施加于PVC花纹面料层2表面，形成胶黏层21。
随后，按照由下至上的顺序依次将EVA泡棉层、三聚氰胺耐磨纸层、SPC基材层、PVC花纹面料层2和三聚氰胺耐磨纸层铺设于多层热压设备的模具；于130℃、21MPa条件下进行热压，控制热压时间为60min。
完成热压后，自然冷却至室温，脱模得复合地板。将制得的复合地板于室温条件下养生24h后，进行回火。回火同样在多层热压设备上完成，回火温度为80℃、回火时间为20min。完成回火后出片，控制出片温度≤80℃，然后自然冷却至室温得成品复合地板。
实施例3：
一种复合地板，参照图1，其包括依次设置的耐磨层1、PVC花纹面料层2、基材层3、平衡层4和静音层5。其中，耐磨层1为三聚氰胺耐磨纸层；基材层3为WPC基材层；平衡层4由PVC膜和三聚氰胺平衡纸复合而成，且PVC膜复合于基材层3；静音层5为IXPE泡棉层。
参照图2，PVC花纹面料层2包括本体层23和由油性PVC油墨在本体层23的正面印刷形成的花纹层22。PVC花纹面料层2的正反两面均设置有胶黏层21。胶黏层21由按照如下配比配置的胶水涂覆而成：
氯化橡胶 3g
过氯乙烯树脂 10g
改性低分子聚酰胺热熔胶 3g
高支化妥尔油树脂 3g
抗氧剂801 1g
乙酸丁酯 50g
丁酮 30g，
其中改性低分子聚酰胺热熔胶为己二酸改性低分子聚酰胺热熔胶。
参照图3，本实施例的复合地板的制造工艺如下：
按照上述配方称取原料，加热熔融混合均匀得预处理用胶水。然后，将预处理用胶水均匀施加于PVC花纹面料层2表面，形成胶黏层21。
随后，按照由下至上的顺序依次将IXPE泡棉、由PVC膜和三聚氰胺平衡纸复合而成的平衡层4、WPC基材层、PVC花纹面料层2和三聚氰胺耐磨纸层铺设于多层热压设备的模具；于140℃、10MPa条件下进行热压，控制热压时间为40min。
完成热压后，自然冷却至室温，脱模得复合地板。将制得的复合地板于室温条件下养生24h后，进行回火。回火同样在多层热压设备上完成，回火温度为100℃、回火时间为10min。完成回火后出片，控制出片温度≤80℃，然后自然冷却至室温得成品复合地板。
实施例4：
一种复合地板，参照图1，其包括依次设置的耐磨层1、PVC花纹面料层2、基材层3、平衡层4和静音层5。其中，耐磨层1为三聚氰胺耐磨纸层；基材层3为SPC基材层；平衡层4为三聚氰胺耐磨纸层；静音层5为EVA泡棉层。
参照图2，PVC花纹面料层2包括本体层23和由油性PVC油墨在本体层23的正面印刷形成的花纹层22。PVC花纹面料层2的正反两面均设置有胶黏层21。胶黏层21由按照如下配比配置的胶水涂覆而成：
氯化橡胶 7g
过氯乙烯树脂 12g
改性低分子聚酰胺热熔胶 7g
高支化妥尔油树脂 7g
抗氧剂801 1.0g
抗氧剂808 0.5g
乙酸丁酯 60g
丁酮 30g，
其中改性低分子聚酰胺热熔胶为己二酸改性低分子聚酰胺热熔胶。
参照图3，本实施例的复合地板的制造工艺如下：
按照上述配方称取原料，加热熔融混合均匀得预处理用胶水。然后，将预处理用胶水均匀施加于PVC花纹面料层2表面，形成胶黏层21。
随后，按照由下至上的顺序依次将EVA泡棉层、三聚氰胺耐磨纸层、SPC基材层、PVC花纹面料层2和三聚氰胺耐磨纸层铺设于多层热压设备的模具；于150℃、5MPa条件下进行热压，控制热压时间为20min。
完成热压后，自然冷却至室温，脱模得复合地板。将制得的复合地板于室温条件下养生24h后，进行回火。回火同样在多层热压设备上完成，回火温度为90℃、回火时间为15min。完成回火后出片，控制出片温度≤80℃，然后自然冷却至室温得成品复合地板。
实施例5：
一种复合地板及其制造工艺，本实施例以实施例1为基础，与实施例1的区别仅在于：完成热压后，自然冷却至室温，脱模得复合地板。将制得的复合地板于室温条件下养生5h后，进行回火。
实施例6：
一种复合地板及其制造工艺，本实施例以实施例1为基础，与实施例1的区别仅在于：PVC花纹面料表面未使用配置的胶水进行预涂处理。
对照例1：
一种复合地板及其制造工艺，与实施例1的区别仅在于：热压成型后不进行回火处理。
对照例2：
一种复合地板及其制造工艺，与实施例1的区别仅在于：耐磨层1选择PVC膜。
性能测试
选择相同厚度（12mm）的实施例1-5以及对照例的复合地板作为样品，进行如下试验：
1）参照GB/T17657-2013测量尺寸变化率。测试结果记录如表1所示：
表1.尺寸稳定性测试（80℃6h）结果表
由上表实验数据可知：本发明的复合地板的长度方向和宽度方向尺寸变化均控制在0.25%内，具有优异的尺寸稳定性。同时，对比实施例1、实施例5和对照例1的数据可知，回火可以显著提升复合地板的尺寸稳定性，且脱模后养生时间越长、回火后得到的复合地板尺寸稳定性更佳。
2）参照GB/T17657-2013测定各试样的耐磨性，试验结果记录如表2所示：
表2.耐磨性测试结果表
由上表数据可知，本发明各实施例的复合地板的耐磨性均达9740r以上，具有极佳的耐磨性，远优于设置常规PVC耐磨层的复合地板的耐磨性（对照例2）。
上述具体实施例仅仅是对本发明的解释，其并不是对本发明的限制，本领域技术人员在阅读完本说明书后可以根据需要对本实施例做出没有创造性贡献的修改，但只要在本发明的权利要求范围内都受到专利法的保护。

Claims (9)

1.一种复合地板，其特征在于：包括依次设置的耐磨层(1)、PVC花纹面料层(2)、基材层(3)、平衡层(4)、静音层(5)，所述耐磨层(1)为三聚氰胺耐磨纸层。
2.根据权利要求1所述的复合地板，其特征在于：所述PVC花纹面料层(2)的正面和/或反面设置有胶黏层(21)。
3. 根据权利要求2所述的复合地板，其特征在于：所述胶黏层(21)包括按重量份计的如下组分，
氯化橡胶 2-7份
过氯乙烯树脂 8-12份
改性低分子聚酰胺热熔胶 2-7份
高支化妥尔油树脂 2-7份
抗氧剂 0.5-1.5份
有机溶剂 60-90份。
4.根据权利要求1所述的复合地板，其特征在于：所述基材层(3)分别选自SPC基材层、WPC基材层。
5.根据权利要求1所述的复合地板，其特征在于：所述静音层(5)为软木层或EVA泡棉或IXPE泡棉。
6.根据权利要求1所述的复合地板，其特征在于：所述PVC花纹面料层(2)包括用水性PVC油墨或油性PVC油墨印制的花纹层(22)。
7.根据权利要求1所述的复合地板，其特征在于：所述平衡层(4)为平衡纸层、三聚氰胺耐磨纸层、或PVC膜与三聚氰胺平衡纸层的结合。
8.一种如权利要求1所述的复合地板的制造工艺，其特征在于：包括如下步骤，
铺料：按照由下至上的顺序依次将静音层(5)、平衡层(4)、基材层(3)、PVC花纹面料层(2)、耐磨层(1)铺设于层压设备的模具，所述耐磨层(1)为三聚氰胺耐磨纸层；
热压：于130-150℃、5-21MPa条件下进行热压，热压时间控制在20-60min；
脱模：自然冷却至室温，脱模得复合地板；
回火：于80-100℃条件下对脱模得到的复合地板进行二次热压处理。
9.根据权利要求8所述的复合地板的制造工艺，其特征在于：所述回火工序在脱模得到的复合地板完全冷却后，并养生24h后再进行。
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