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WO2018113325A1 - 用于生产板材发泡层的组合物及包含此组合物的板材及其生产方法 - Google Patents

用于生产板材发泡层的组合物及包含此组合物的板材及其生产方法 Download PDF

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Publication number
WO2018113325A1
WO2018113325A1 PCT/CN2017/097793 CN2017097793W WO2018113325A1 WO 2018113325 A1 WO2018113325 A1 WO 2018113325A1 CN 2017097793 W CN2017097793 W CN 2017097793W WO 2018113325 A1 WO2018113325 A1 WO 2018113325A1
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WIPO (PCT)
Prior art keywords
layer
lubricant
composition
parts
sheet material
Prior art date
Application number
PCT/CN2017/097793
Other languages
English (en)
French (fr)
Inventor
周玉亮
Original Assignee
青岛三益塑料机械有限公司
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from CN201710582639.9A external-priority patent/CN107200967A/zh
Priority claimed from CN201720867694.8U external-priority patent/CN207332219U/zh
Application filed by 青岛三益塑料机械有限公司 filed Critical 青岛三益塑料机械有限公司
Priority to EP17885269.5A priority Critical patent/EP3617266B1/en
Priority to KR1020177030359A priority patent/KR101986136B1/ko
Priority to MYPI2019007866A priority patent/MY189966A/en
Priority to US15/811,628 priority patent/US10633503B2/en
Publication of WO2018113325A1 publication Critical patent/WO2018113325A1/zh

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    • C08J9/08—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a chemical blowing agent developing carbon dioxide
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    • 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
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    • 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

Definitions

  • the present application relates to the field of sheets, in particular to compositions for producing sheet foam layers, to sheets comprising the same, and to a process for the production thereof.
  • PVC plastic sheet is more and more popular among consumers because of its superiority in pressure resistance, waterproof and moisture resistance, wear resistance and environmental protection. However, the stability and superiority of PVC plastic sheet properties are inseparable from its formulation and processing technology.
  • a composition for producing a foam layer of a sheet material comprising a main component and an auxiliary component, the main component is composed of polyvinyl chloride and calcium carbonate, and the auxiliary component includes a regulator and is stable.
  • Agent, lubricant, foaming agent in terms of parts by weight, polyvinyl chloride is 75 parts, calcium carbonate is 75-80 parts, regulator is 6-8 parts, stabilizer is 3-5 parts, lubricant is 0.7. - 1.4 parts; the blowing agent is 0.2-0.7 parts.
  • it also includes a return material which accounts for 5-25% of the total mass of the foamed layer composition.
  • the lubricant comprises an inner lubricant and an outer lubricant.
  • the mass ratio of the inner lubricant to the outer lubricant is from 2:1 to 3:1.
  • the internal lubricant is one or more of stearic acid, a polyol hard fatty acid, and an oxidized polyethylene wax.
  • the external lubricant is a polyethylene wax.
  • the blowing agent comprises a white blowing agent and a yellow blowing agent.
  • the mass ratio of the white foaming agent to the yellow foaming agent is from 1:1 to 3:7.
  • the mass ratio of the white foaming agent to the yellow foaming agent is from 1:1 to 3:1.
  • the white blowing agent is sodium hydrogencarbonate.
  • the yellow blowing agent is azodicarbonamide.
  • the application also provides a board comprising the composition as previously described.
  • the sheet material comprises a foam layer in the intermediate layer and a solid layer on both sides of the foam layer and extruded integrally with the foam layer.
  • the surface of the solid layer on one side of the foam layer is provided with a non-slip layer.
  • the surface of the solid layer on one side of the foam layer is provided with a color film layer.
  • the surface of the color film layer is provided with a wear layer.
  • the solid layer is divided into an upper solid layer and a lower solid layer, wherein the upper solid layer and the lower solid layer have thicknesses of 1-1.5 mm and 0.3-0.5 mm, respectively; and the thickness of the foam layer is 2.5.
  • the thickness of the anti-slip layer is 0.15-0.3 mm; the thickness of the wear-resistant layer is 0.15-0.5 mm; and the thickness of the color film layer is 0.07-0.08 mm.
  • a composition for producing a solid layer of a board comprising a main component and an auxiliary component, the main component consisting of polyvinyl chloride and calcium carbonate, the auxiliary component comprising a regulator, a stabilizer, a lubricant;
  • the polyvinyl chloride is 50 parts
  • the calcium carbonate is 50-55 parts
  • the regulator is 2-7 parts
  • the stabilizer is 2-4 parts
  • the lubricant is 0.5-1.1 parts.
  • the composition for producing a solid layer of the board further comprises a plasticizer, the plasticizer comprising from 1 to 8% by total mass of the solid layer composition.
  • the plasticizer is dioctyl phthalate or epoxidized soybean oil.
  • the plasticizer is dioctyl phthalate, epoxidized soybean oil or dioctyl terephthalate.
  • the lubricant used in the composition for producing a solid layer of the board comprises an inner lubricant and an outer lubricant.
  • the mass ratio of the inner lubricant to the outer lubricant is from 2:1 to 3:1.
  • the internal lubricant is one or more of stearic acid, a polyol hard fatty acid, and an oxidized polyethylene wax.
  • the external lubricant is a polyethylene wax.
  • the application also provides a method of producing a sheet material as described above, comprising the steps of:
  • composition for producing the foam layer of the sheet and the composition for producing the solid layer of the sheet are respectively mixed, firstly mixed by heat, and when the temperature reaches 105-120 ° C, the mixture is cooled and stirred;
  • the melt of the two materials is in the form of a foam layer in the middle layer, and the solid layer in the form of two sides of the foam layer Forming through a dispenser into a mold cavity of 160-180 ° C;
  • Crop Cool and cut the sheet.
  • the surface of the color film layer or/and the surface of the non-slip layer are embossed at 130-180 ° C, respectively.
  • the beneficial effects of the present application are as follows: the components of the foam layer and the solid layer used for producing the plate material do not contain the glue substance, and the process of the glue-free compounding process in the production process is very environmentally friendly and healthy.
  • the sheet produced by the present formulation and the process is formed by foaming polyvinyl chloride to form a foamed layer, and a solid layer obtained by unexpanding polyvinyl chloride is coextruded on both sides of the foamed layer to form a core layer of the sheet.
  • the produced sheet is both light and superior to the performance of the traditional sheet, that is, it has excellent pressure resistance, warpage and shrinkage properties, and is waterproof, moisture-proof and insect-proof.
  • This production process saves several steps compared with the traditional production process, which not only saves equipment investment, but also saves power consumption and labor costs.
  • the process does not require sanding, there is no dust, it is more environmentally friendly, and the production capacity and yield are high.
  • the present application relates to a composition for producing a foam layer of a sheet material, comprising a main component and an auxiliary component, wherein the main component is composed of polyvinyl chloride (PVC) and calcium carbonate, and the auxiliary component includes a regulator, a stabilizer, and a lubricant.
  • foaming agent in terms of parts by weight, polyvinyl chloride is 75 parts, calcium carbonate is 75-80 parts, the regulator is 6-8 parts, the stabilizer is 3-5 parts, the lubricant is 0.7-1.4 parts;
  • the blowing agent is 0.2-0.7 parts.
  • a foamed layer prepared by the above composition for producing a foamed layer of a sheet which is formed by foaming polyvinyl chloride to reduce the weight of the sheet as a whole, but irregular voids may occur in the middle of the foamed sheet.
  • the voids can cause the sheet to have a weak pressure resistance, and can be supported by the filling of calcium carbonate, that is, through the polyvinyl chloride and calcium carbonate. Cooperating with each other, it can save the amount of PVC, while ensuring that the sheet has sufficient compressive properties and good warpage and shrinkage properties.
  • the calcium carbonate used in the composition for producing a foamed layer of a sheet material is active light calcium carbonate.
  • the active light calcium carbonate refers to light calcium carbonate treated with an activator, and those skilled in the art can select within the range of 75-80 parts according to the different requirements of the compressive performance of the sheet, for example, : 76 parts, 77 parts, 78 parts, 79 parts, etc.
  • the regulator used in the composition for producing a foam layer of a sheet material is a commercially available chemical auxiliary agent, and its main function is to adjust foaming and increase plasticizing effect, so that polyvinyl chloride can exhibit better foaming.
  • the effect is to promote plasticization to improve melt strength, prevent bubbles from merging or cracking, high molecular weight viscosity melt, ensure sufficient foamed melt, improve fluidity and surface finish.
  • the regulator is an acrylate (ACR) series impact plasticizing aid.
  • ACR is a kind of acrylic acid polymer copolymer, which has strong promotion of plasticization and flow improvement for PVC. It can significantly reduce the deposition of various added components on the processing surface and improve productivity, especially for the processing of hard products.
  • the stabilizer used in the composition for producing the foam layer of the sheet material is a commercially available chemical auxiliary agent, and may be a calcium zinc stabilizer or a composite stabilizer, and its main function is to inhibit the early decomposition of the polyvinyl chloride during processing, so that The formulation system has sufficient stability.
  • the composition for producing a foamed layer of a sheet material further comprises a recycled material which accounts for 5 to 25% of the total mass of the foamed layer composition.
  • the return material is the material after the crushing and recycling of the scrap material produced in the production process.
  • the return material can also be 10%, 12%, 15%, 18%, 20%, etc. of the total mass of the foam layer composition.
  • the lubricant includes an inner lubricant and an outer lubricant.
  • the role of the external lubricant is mainly to improve the friction between the polymer melt and the hot metal surface of the processing equipment. It has poor compatibility with the polymer and is easy to migrate from the inside of the melt, so it can be in the intersection of the plastic melt and the metal. The interface forms a thin layer of lubrication.
  • the internal lubricant has good compatibility with the polymer, and it acts to reduce the cohesive force between the polymer molecules inside the polymer, thereby improving the internal friction heat generation and melt flowability of the plastic melt.
  • the lubricant includes an inner lubricant and an outer lubricant, and the mass ratio of the inner lubricant to the outer lubricant is 2:1-3:1.
  • the internal lubricant is one or more of stearic acid, a polyol hard fatty acid, and an oxidized polyethylene wax; the external lubricant is a polyethylene wax.
  • the foaming agent comprises a white foaming agent and a yellow foaming agent
  • the white foaming agent and the yellow foaming agent are all commercially available chemical auxiliary agents, white foaming agents and yellow foaming agents.
  • the mass ratio is 1:1-3:7.
  • the mass ratio of the two can be taken within the above range
  • the value may be specifically determined depending on the density of the foamed layer and the amount of calcium carbonate, and may be, for example, 4:7, 5:7, 6:7, or the like.
  • the foaming agent comprises a white foaming agent and a yellow foaming agent
  • the white foaming agent and the yellow foaming agent are all commercially available chemical auxiliary agents, white foaming agents and yellow foaming agents.
  • the mass ratio is 1:1-3:1.
  • the mass ratio of the two may be in the above range, depending on the density of the foam layer and the amount of calcium carbonate. For example, it may be: 5:3, 6:3, 7:3, 8:3. Wait.
  • the main function of the white foaming agent is to absorb heat.
  • the main function of the yellow foaming agent is to release heat.
  • the foaming agent used in the composition for producing the foam layer of the present invention needs to be jointly prepared by a white foaming agent and a yellow foaming agent.
  • a single foaming agent can not achieve the desired foaming effect, that is, it has the similar weight of traditional wooden flooring, and it has an ideal Compression, warpage and shrinkage properties.
  • a white foaming agent is not added, the resulting foamed layer may be burnt, causing the foamed layer to discolor and affecting the quality of the foamed layer.
  • the white blowing agent is sodium hydrogencarbonate; the yellow blowing agent is azodicarbonamide.
  • the application also provides a board comprising the composition as previously described.
  • the sheet provided by the present application comprises a foamed layer in the intermediate layer and a solid layer on both sides of the foamed layer and extruded integrally with the foamed layer, as shown in FIG.
  • the surface of the solid layer 3 on the side of the foamed layer 4 is provided with a non-slip layer 5.
  • the anti-slip layer is disposed on the side of the board near the wall or the ground to prevent the sheet from sliding.
  • the surface of the solid layer 3 on the side of the foamed layer 4 is provided with a color film layer 2. Due to the aesthetic needs, the side of the panel facing the user is combined with a color film layer, and the pattern and color of the color film layer can be adjusted by itself to match the preferences of the consumer and the decoration of the building decoration. When the sheet needs to face both sides of the user, a color film layer may be attached to the surface of the two solid layers, and the pattern and color of the color film layer may be different.
  • the surface of the color film layer 2 is provided with a wear resistant layer 1.
  • the wear-resistant layer 1 can function to protect the color film layer and the plate itself, and has the functions of preventing pattern wear or color loss of the color film layer, waterproof, moisture-proof, insect-proof and the like.
  • the corresponding side of the panel is provided with a latch 6 for mounting the connection and a slot 7 for receiving the latch.
  • the solid layer is divided into an upper solid layer on a side of the sheet in contact with the user, and a lower solid layer on a side of the sheet in contact with the panel mounting surface, wherein the solid layer is solid
  • the thickness of the layer and the lower solid layer are respectively 1-1.5 mm and 0.3-0.5 mm; the thickness of the foam layer is 2.5-3.5 mm; the thickness of the anti-slip layer is 0.15-0.3 mm; the thickness of the wear layer is 0.15-0.5 mm; The layer thickness is 0.07-0.08 mm.
  • the composition for producing a solid layer of a plate material comprises a main component and an auxiliary component, the main component is composed of polyvinyl chloride and calcium carbonate, and the auxiliary component comprises a regulator, a stabilizer, a lubricant;
  • the number of parts is 50 parts of polyvinyl chloride, 50-55 parts of calcium carbonate, 2-7 parts of a regulator, 2-4 parts of a stabilizer, and 0.5-1.1 parts of a lubricant.
  • Calcium carbonate is a filler, and the addition of calcium carbonate can reduce the cost and at the same time improve the stability of the solid layer.
  • the solid layer is on both sides of the foamed layer and does not contain a blowing agent, i.e., a process that does not undergo foaming, because the solid layer needs to provide a protective and supporting effect on the foamed layer.
  • a blowing agent i.e., a process that does not undergo foaming
  • the foamed layer and the solid layer are integrally extruded, they become the main structure of the board, so that the board has both the lightness of the traditional wooden board and the firmness of the traditional stone-plastic material.
  • the regulator 401 promotes the plasticization of the material in the early stage, and belongs to the acrylate type (ACR) series of impact plasticizing aids.
  • CPE is a toughening and impact-resistant additive that increases the strength and flexibility of the product and increases the surface hardness.
  • the composition for producing a solid layer of a plate further comprises a plasticizer, which is a commercially available chemical auxiliary, and the plasticizer accounts for 1 of the total mass of the solid layer composition. -8%, can improve the effect of plasticization.
  • a plasticizer which is a commercially available chemical auxiliary, and the plasticizer accounts for 1 of the total mass of the solid layer composition. -8%, can improve the effect of plasticization.
  • the addition amount of the plasticizer those skilled in the art can select within the above range according to the actual plasticizing effect required, for example, 2%, 4%, 5%, 6%, 7%, and the like.
  • the plasticizer is dioctyl phthalate (DOP) or epoxidized soybean oil.
  • the plasticizer is dioctyl phthalate (DOP), epoxidized soybean oil or dioctyl terephthalate (DOTP).
  • the lubricant used in the composition for producing a solid layer of a sheet material includes an inner lubricant and an outer lubricant, and the inner lubricant and the outer lubricant function as described above.
  • the mass ratio of the inner lubricant to the outer lubricant is 2:1-3:1.
  • the internal lubricant in the composition for producing a solid layer of a sheet material is one or more of stearic acid, a polyol hard fatty acid and an oxidized polyethylene wax;
  • the external lubricant in the composition for producing the solid layer of the board is a polyethylene wax.
  • the application also provides a method of producing a sheet material as described above, comprising the steps of:
  • composition for producing the foam layer of the sheet and the composition for producing the solid layer of the sheet are respectively mixed, firstly mixed by heat, and when the temperature reaches 105-120 ° C, the mixture is cooled and stirred;
  • the melt of the two materials is a foamed layer according to the intermediate layer, and the sides of the foamed layer are in the form of a solid layer Forming through a dispenser into a mold cavity of 160-180 ° C;
  • Crop Cool and cut the sheet.
  • the intermediate layer is a foamed layer, although a three-layer co-extruded layer has been formed after the extrusion of the mold, but Since the intermediate layer is a foamed layer, the intermediate layer after the discharge will have a wave shape, and the solid layer on both sides of the foamed layer will also have a wave shape along with the foamed layer, so that the flattening device is used for instantaneous cooling and flattening. It can make the co-extruded layer of the board more flat, which is beneficial to ensure the quality of the product.
  • the molding machine After cooling and flattening, it enters the molding machine and performs the process of compounding while setting. Since the temperature is too high, the secondary foaming phenomenon will occur. Therefore, the low temperature cooling is performed for a period of time and then heated and compounded.
  • the temperature of the molding machine is from low to high. As the sheet is conveyed, the front roller temperature is lower, and the subsequent roller temperature is higher. Under normal circumstances, the front roller temperature is 40-80 ° C, and the subsequent roller temperature is 100-160. °C, when the composite temperature is reached, the other composite layers are conveyed to the molding machine through other conveying equipment, and are combined with the co-extruded layer.
  • the compounding process is adjusted according to the needs of the product, and may be a composite anti-slip layer, a composite color film layer, or a composite color film layer, a composite anti-slip layer, or both.
  • the anti-slip layer can be replaced with a color film layer.
  • the surface of the color film layer needs a composite wear layer, that is, the wear layer is placed on the surface of the color film layer by a transfer device, and compacted at 130-180 ° C to form a plate.
  • the color film layer can also be omitted.
  • the anti-slip layer can also be omitted.
  • the surface of the color film layer or/and the surface of the abrasion resistant layer are embossed at 130-180 ° C, respectively.
  • the embossing process can be selected or not, and can be customized according to the product requirements.
  • the flower roll can be replaced by a light roller.
  • the molding machine is shaped and compounded in one step, thereby realizing one-step molding of the plate production.
  • the traditional wood-plastic sheet processing process is extrusion substrate - sanding surface - coating - laminating - stacking - cold pressing - health - slitting - slotting - testing packaging - setting - storage boxing.
  • the one-step processing process of the present application is a one-step molding-healing-cutting-grooving-testing packaging-setting-into the storage box.
  • the health is to place the formed plate for a period of time to adapt to the humidity of the surrounding environment.
  • the plate after the health is not easily deformed in the next step.
  • the one-step production process of the present application dispenses with five processes while eliminating the following inputs:
  • the material is saved, for example, glue is needed before fitting; at the same time, the composition of the glue is not good for health;
  • the material of the board is soft and elastic. It has good elastic recovery under the impact of heavy objects, which can greatly reduce the slippage and falls of the personnel. At the same time, the impact damage to the heavy objects also has good elastic recovery and will not cause damage;
  • the board has the characteristics of water and sputum, and at the same time have done anti-slip treatment (wear layer pattern);
  • the plate can be processed into a variety of colors and patterns, the user's pattern can be more widely selected, can be customized;
  • the finished product density can be arbitrarily controlled within 0.9T/m 3 -1.2T/m 3 ;
  • the shrinkage rate is one to two times lower than that of traditional wood-plastic panels
  • the substrate part can realize multi-layer composite in the mold, and then, like the SPC (stone plastic) floor, the color film and the wear-resistant layer material are synchronously compounded, and the product can be sold directly after the product is off the slot and UV;
  • OA6 Oxidized Polyethylene Wax
  • OA6 Oxidized Polyethylene Wax
  • PE wax is an external lubricant for PVC processing, which adjusts the plasticizing time and increases the surface finish of the product.
  • the plasticizing time is short, the adhesion is serious, and the thermal stability is poor; in excess, precipitation occurs and the scale in the mold is formed.
  • 60 is an internal lubricant, which adjusts the slidability in the PVC material, reduces the internal friction of the melt, reduces the current, and assists the material to be uniformly plasticized. If used excessively, the melt viscosity is destroyed.
  • composition for producing the foamed layer of the sheet and the composition for producing the solid layer of the sheet are respectively mixed, firstly subjected to hot mixing, and when the temperature reaches 105-110 ° C, the mixture is cooled and stirred;
  • the solid layer material is stirred while the DOP (because it is a liquid) is slowly poured into the rotating mixer, so that the stirring is relatively uniform;
  • the melt of the two materials is in the form of a foam layer in the middle layer, and the two sides of the foam layer are in the form of a solid layer, and the mold is introduced into the mold cavity of 160-180 ° C for molding;
  • Crop Cool and cut the sheet.
  • composition for producing the foam layer of the sheet and the composition for producing the solid layer of the sheet are respectively mixed, firstly mixed by heat, and when the temperature reaches 110-115 ° C, the mixture is cooled and stirred;
  • the melt of the two materials is in the form of a foam layer in the middle layer, and the two sides of the foam layer are in the form of a solid layer, and the mold is introduced into the mold cavity of 165-170 ° C for molding;
  • Crop Cool and cut the sheet.
  • composition for producing the foam layer of the sheet and the composition for producing the solid layer of the sheet are separately mixed, firstly mixed by heat, and when the temperature reaches 115-120 ° C, the mixture is cooled and stirred;
  • the melt of the two materials is in the form of a foam layer in the middle layer, and the two sides of the foam layer are in the form of a solid layer, and the mold is introduced into the mold cavity of 170-180 ° C for molding;
  • Crop Cool and cut the sheet.
  • the raw materials were prepared according to Table 4, and Table 4 is the amount of one batch.
  • composition for producing the foam layer of the sheet and the composition for producing the solid layer of the sheet are respectively mixed, firstly mixed by heat, and when the temperature reaches 105-120 ° C, the mixture is cooled and stirred;
  • the melt of the two materials is in the form of a foam layer in the middle layer, and the two sides of the foam layer are in the form of a solid layer, and the mold is introduced into the mold cavity of 160-180 ° C for molding;
  • Crop Cool and cut the sheet.
  • composition for producing the foam layer of the sheet and the composition for producing the solid layer of the sheet are respectively mixed, firstly mixed by heat, and when the temperature reaches 105-120 ° C, the mixture is cooled and stirred;
  • the melt of the two materials is in the form of a foam layer in the middle layer, and the two sides of the foam layer are in the form of a solid layer, and the mold is introduced into the mold cavity of 160-180 ° C for molding;
  • Crop Cool and cut the sheet.

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Abstract

本申请涉及用于生产板材发泡层的组合物，包括主要成分和辅助成分，其中，主要成分由聚氯乙烯(PVC)和碳酸钙组成，辅助成分包括调节剂、稳定剂、润滑剂、发泡剂；按照重量份数计，聚氯乙烯为75份，碳酸钙为75-80份，调节剂为6-8份，稳定剂为3-5份，润滑剂为0.7-1.4份；发泡剂为0.2-0.7份。本用于生产板材的发泡层和实心层的组分中不含胶类物质，同时生产工艺中不含涂胶复合的过程，非常环保健康。通过本配方和本工艺生产得到的板材，通过聚氯乙烯发泡形成发泡层并且将聚氯乙烯未经发泡制得的实心层在发泡层的两侧共挤形成板材的核心层，具有优良的抗压、翘曲和收缩性能，并且防水、防潮、防虫，且工序简单。

Description

用于生产板材发泡层的组合物及包含此组合物的板材及其生产方法 技术领域
本申请涉及板材领域，具体的说是用于生产板材发泡层的组合物及包含此组合物的板材及其生产方法。
背景技术
PVC塑胶板材由于其抗压、防水防潮、耐磨、环保等方面的优越性，越来越受消费者的青睐。但是，PVC塑胶板材性能的稳定性及优越性与其配方和加工工艺密不可分。
中国专利申请CN 103481517 A《一种PVC塑胶地板的生产工艺》，公开了将聚氯乙烯(PVC)混合粉、增塑剂、碳酸钙、稳定剂、石蜡、松香和碳粉经过混合、密炼、压延、冷却、裁片、入库养生、铺膜、烧制、养生、PU处理、物理处理、常温养生、成型、检测包装得到PVC塑胶地板。但是，此加工工艺非常复杂，材料消耗大，人工利用多，这无疑增加了产品的成本。
发明内容
根据上述不足之处，本申请的目的在于：提供一种用于生产板材发泡层的组合物及包含此组合物的板材及其生产方法。
为实现上述目的，本申请的技术方案在于：一种用于生产板材发泡层的组合物，包括主要成分和辅助成分，主要成分由聚氯乙烯和碳酸钙组成，辅助成分包括调节剂、稳定剂、润滑剂、发泡剂；按照重量份数计，聚氯乙烯为75份，碳酸钙为75-80份，调节剂为6-8份，稳定剂为3-5份，润滑剂为0.7-1.4份；发泡剂为0.2-0.7份。
优选的是：还包括回料，回料占发泡层组合物总质量的5-25％。
优选的是：润滑剂包括内润滑剂和外润滑剂。
优选的是：内润滑剂和外润滑剂的质量比为2:1-3:1。
优选的是：内润滑剂为硬脂酸、多元醇硬脂肪酸和氧化聚乙烯蜡中的一种或多种。
优选的是：外润滑剂为聚乙烯蜡。
优选的是：发泡剂包括白发泡剂和黄发泡剂。
优选的是：白发泡剂和黄发泡剂的质量比为1:1-3:7。
优选的是：白发泡剂和黄发泡剂的质量比为1:1-3:1。
优选的是：白发泡剂为碳酸氢钠。
优选的是：黄发泡剂为偶氮二甲酰胺。
本申请还提供一种板材，包含有如前所述的组合物。
优选的是：板材包括位于中间层的发泡层和位于发泡层的两侧并与发泡层一体式挤出的实心层。
优选的是：发泡层一侧的实心层的表面设有防滑层。
优选的是：发泡层一侧的实心层的表面设有彩膜层。
优选的是：彩膜层的表面设有耐磨层。
优选的是：所述实心层分为上实心层和下实心层，其中，上实心层和下实心层的厚度分别为1-1.5mm和0.3-0.5mm；所述发泡层的厚度为2.5-3.5mm；所述防滑层的厚度为0.15-0.3mm；所述耐磨层的厚度为0.15-0.5mm；所述彩膜层的厚度为0.07-0.08mm。
优选的是：用于生产板材实心层的组合物，包括主要成分和辅助成分，主要成分由聚氯乙烯和碳酸钙组成，辅助成分包括调节剂、稳定剂、润滑剂；按重量份数计，聚氯乙烯为50份，碳酸钙为50-55份，调节剂为2-7份，稳定剂为2-4份、润滑剂为0.5-1.1份。
优选的是：所述用于生产板材实心层的组合物还包括增塑剂，增塑剂占实心层组合物总质量的1-8％。
优选的是：增塑剂为邻苯二甲酸二辛酯或者环氧大豆油。
优选的是：增塑剂为邻苯二甲酸二辛酯、环氧大豆油或对苯二甲酸二辛酯。
优选的是：用于生产板材实心层的组合物中润滑剂包括内润滑剂和外润滑剂。
优选的是：内润滑剂和外润滑剂的质量比为2:1-3:1。
优选的是：内润滑剂为硬脂酸、多元醇硬脂肪酸和氧化聚乙烯蜡中的一种或多种。
优选的是：外润滑剂为聚乙烯蜡。
本申请还提供一种生产如前所述的板材的方法，包括如下步骤：
(1)混料：将用于生产板材发泡层的组合物和用于生产板材实心层的组合物分别进行混料，先进行热混，当温度到达105-120℃时，再冷却搅拌；
(2)熔融：当物料温度降低至30-40℃时，将两种混合后的物料分别上料至挤出机的料斗，两种物料分别经事先预热至150-180℃的挤出机进行加热挤压成为熔体；
(3)分配成型：两种物料的熔体按照中间层为发泡层，发泡层的两侧为实心层的形式 经过分配器进入160-180℃的模具腔内进行成型；
(4)定型复合：首先将成型的实心层和发泡层一起在20-50℃下冷却压平，随后温度逐渐升高；然后将需要复合的彩膜层或/和防滑层分别通过传输设备置于两层实心层的两侧，在130-180℃下进行压实复合，最后将耐磨层通过传输设备置于彩膜层的表面，在130-180℃下进行压实复合，形成板材；
(5)裁剪：对板材进行冷却，裁剪。
优选的是：防滑层或/和彩膜层复合后，分别在130-180℃下，对彩膜层的表面或/和防滑层的表面进行压纹。
本申请的有益效果在于：本申请用于生产板材的发泡层和实心层的组分中不含胶类物质，同时生产工艺中不含涂胶复合的过程，非常环保健康。通过本配方和本工艺生产得到的板材，通过聚氯乙烯发泡形成发泡层并且将聚氯乙烯未经发泡制得的实心层在发泡层的两侧共挤形成板材的核心层，使得生产得到的板材既轻便，又具有优于传统板材性能的特点，即具有优良的抗压、翘曲和收缩性能，并且防水、防潮、防虫。本生产工艺较传统的生产工艺节省了好几个步骤，不仅节约了设备投入，并且节约耗电量和人工费，本工艺不需要砂光，就没有粉尘，更加环保，且产能和成品率高。
附图说明
图1是本申请的结构示意图
图中，1-耐磨层；2-彩膜层；3-实心层；4-发泡层；5-防滑层；6-锁扣；7-槽。
具体实施方式
下面结合具体实施例对本申请做进一步说明。
本申请涉及一种用于生产板材发泡层的组合物，包括主要成分和辅助成分，其中，主要成分由聚氯乙烯(PVC)和碳酸钙组成，辅助成分包括调节剂、稳定剂、润滑剂、发泡剂；按照重量份数计，聚氯乙烯为75份，碳酸钙为75-80份，调节剂为6-8份，稳定剂为3-5份，润滑剂为0.7-1.4份；发泡剂为0.2-0.7份。
由上述用于生产板材发泡层的组合物制备得到的发泡层，其通过将聚氯乙烯进行发泡，整体降低板材的重量，但是发泡后的板材中间会出现不规则的空隙，这些空隙会导致板材的抗压性较弱，通过碳酸钙的填充，可以起到支撑的作用，也就是说通过聚氯乙烯和碳酸钙的 相互配合，既能节约聚氯乙烯的用量，同时又能确保板材具有足够的抗压性能及良好的翘曲和收缩性能。
所述用于生产板材发泡层的组合物中所采用的碳酸钙为活性轻质碳酸钙。所述活性轻质碳酸钙是指用活化剂处理后的轻质碳酸钙，本领域技术人员可根据板材的抗压性能的不同要求，在上述75-80份范围内进行选取，例如还可以为：76份、77份、78份、79份等。
所述用于生产板材发泡层的组合物中所采用的调节剂为市售的化工助剂，其主要作用是调节发泡，增加塑化效果，使得聚氯乙烯可以呈现更好的发泡效果，促进塑化提高熔体强度，防止气泡合并或破裂，高分子量粘度熔体，保证充足的发泡熔体，提高流动性和表面光洁度。作为一种优选的实施方式，所述调节剂为丙烯酸酯类(ACR)系列抗冲类塑化助剂。ACR为丙稀酸脂类高分子共聚物,对PVC有较强的促进塑化和改善流动作用,能显著地减少各种添加成份在加工表面沉积，提高生产率，尤其适合硬质品的加工。
本用于生产板材发泡层的组合物中所采用的稳定剂为市售的化工助剂，可以是钙锌稳定剂或者复合稳定剂，其主要作用是加工中抑制聚氯乙烯提前分解，使得配方体系拥有足够的稳定性。
作为一种优选的实施例，本用于生产板材发泡层的组合物中还包括回料，回料占发泡层组合物总质量的5-25％。回料就是在生产过程中产生的边角料废板破碎回收后的料。通过采用回料，可以在一定程度上降低原料的使用，降低成本。本领域技术人员可根据实际需要在上述范围内进行选择，例如回料还可以为发泡层组合物总质量的10％、12％、15％、18％、20％等。
作为一种优选的实施例，润滑剂包括内润滑剂和外润滑剂。外润滑剂的作用主要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，容易从熔体内往外迁移，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。
其中，润滑剂包括内润滑剂和外润滑剂，内润滑剂和外润滑剂的质量比为2:1-3:1。
作为一种优选的实施例，内润滑剂为硬脂酸、多元醇硬脂肪酸和氧化聚乙烯蜡中的一种或多种；所述的外润滑剂为聚乙烯蜡。
作为一种优选的实施例，发泡剂包括白发泡剂和黄发泡剂，白发泡剂和黄发泡剂均为市售的化工助剂，白发泡剂和黄发泡剂的质量比为1:1-3:7。两者的质量比可在上述范围内取 值，具体可根据发泡层的密度和碳酸钙的用量而定，例如，还可以为：4:7、5:7、6:7等。
作为一种优选的实施例，发泡剂包括白发泡剂和黄发泡剂，白发泡剂和黄发泡剂均为市售的化工助剂，白发泡剂和黄发泡剂的质量比为1:1-3:1。两者的质量比可在上述范围内取值，具体可根据发泡层的密度和碳酸钙的用量而定，例如，还可以为：5:3、6:3、7:3、8:3等。
白发泡剂的主要作用是吸收热量，黄发泡剂的主要作用是释放热量，本申请用于生产板材发泡层的组合物中发泡剂需要由白发泡剂和黄发泡剂共同作用，才能对聚氯乙烯起到很好的发泡的效果，单一一种发泡剂都不能达到理想的发泡效果，即，既要有传统木质地板相似的重量，又要有理想的抗压、翘曲和收缩性能。例如，如果不加白发泡剂，生产出来的发泡层会出现烧心的现象，使得发泡层变色，影响发泡层的质量。
作为一种优选的实施例，白发泡剂为碳酸氢钠；黄发泡剂为偶氮二甲酰胺。本申请还提供一种板材，包含有如前所述的组合物。
本申请提供的板材包括位于中间层的发泡层和位于发泡层的两侧并与发泡层一体式挤出的实心层，如图1所示。
作为一种优选的实施例，发泡层4一侧的实心层3的表面设有防滑层5。当板材需要与墙面或者地面进行安装时，防滑层是设置在板材靠近墙面或者地面的一侧，起到防止板材滑动的作用。
作为一种优选的实施例，发泡层4一侧的实心层3的表面设有彩膜层2。因审美的需要，板材面对使用者的一侧复合上彩膜层，彩膜层的图案和色彩可以自行调整，以配合消费者的喜好以及建筑装饰的搭配。当板材需要双面都面对使用者时，可以在两层实心层的表面均附上彩膜层，并且彩膜层的图案和色彩可以不一样。
作为一种优选的实施例，彩膜层2的表面设有耐磨层1。耐磨层1可以起到保护彩膜层和板材本身的作用，具有防止彩膜层的图案磨损或是色彩流失，防水防潮防虫蛀等作用。
作为一种优选的实施例，板材相对应的侧面设有用于安装连接的锁扣6和用于容纳锁扣的槽7。
实心层分为上实心层和下实心层，所述上实心层位于所述板材与用户接触的一侧，所述下实心层位于所述板材与板材安装面接触的一侧，其中，上实心层和下实心层的厚度分别为1-1.5mm和0.3-0.5mm；发泡层厚度为2.5-3.5mm；防滑层厚度为0.15-0.3mm；耐磨层厚度为0.15-0.5mm；彩膜层厚度为0.07-0.08mm。
作为一种优选的实施例，用于生产板材实心层的组合物，包括主要成分和辅助成分，主要成分由聚氯乙烯和碳酸钙组成，辅助成分包括调节剂、稳定剂、润滑剂；按重量份数计，聚氯乙烯为50份，碳酸钙为50-55份，调节剂为2-7份，稳定剂为2-4份、润滑剂为0.5-1.1份。碳酸钙属于填充料，添加碳酸钙可以降低成本，同时起到提高实心层稳定性的作用。
实心层在发泡层的两侧，并且不含发泡剂，即不经过发泡的过程，这是因为实心层需要对发泡层起到一个保护和支撑的作用。当发泡层和实心层一体式挤出后成为板材的主体结构，使得板材兼具传统木制板材的轻便性和传统石塑材料的结实程度。
用于生产板材实心层的组合物中的调节剂为两种，一种是调节剂401，一种是调节剂氯化聚乙烯(CPE)，均为市售的化工助剂。调节剂401促使物料前期塑化，属丙烯酸酯类(ACR)系列抗冲类塑化助剂。CPE属增韧抗冲类助剂，增加制品的强度及柔韧性，提高表面硬度。
作为一种优选的实施例，所述用于生产板材实心层的组合物还包括增塑剂，所述增塑剂为市售的化工助剂，增塑剂占实心层组合物总质量的1-8％，可以提高塑化的效果。对于增塑剂的添加量，本领域技术人员可根据实际所需的塑化效果，在上述范围内进行选择，例如还可以为：2％、4％、5％、6％、7％等。
作为一种优选的实施例，增塑剂为邻苯二甲酸二辛酯(DOP)或者环氧大豆油。
作为一种优选的实施例，增塑剂为邻苯二甲酸二辛酯(DOP)、环氧大豆油或对苯二甲酸二辛酯(DOTP)。
作为一种优选的实施例，所述用于生产板材实心层的组合物中的润滑剂包括内润滑剂和外润滑剂，内润滑剂和外润滑剂的作用如前所述。其中，内润滑剂和外润滑剂的质量比为2:1-3:1。
作为一种优选的实施例，所述用于生产板材实心层的组合物中的内润滑剂为硬脂酸、多元醇硬脂肪酸和氧化聚乙烯蜡中的一种或多种；所述用于生产板材实心层的组合物中的外润滑剂为聚乙烯蜡。
本申请还提供一种生产如前所述的板材的方法，包括如下步骤：
(1)混料：将用于生产板材发泡层的组合物和用于生产板材实心层的组合物分别进行混料，先进行热混，当温度到达105-120℃时，再冷却搅拌；
(2)熔融：当物料温度降低至30-40℃时，将两种混合后的物料分别上料至挤出机的料斗，两种物料分别经事先预热至150-180℃的挤出机进行加热挤压成为熔体；
(3)分配成型：两种物料的熔体按照中间层为发泡层，所述发泡层的两侧为实心层的形 式经过分配器进入160-180℃的模具腔内进行成型；
(4)定型复合：首先将成型的实心层和发泡层一起在20-50℃下冷却压平，随后温度逐渐升高；然后将需要复合的彩膜层或/和防滑层分别通过传输设备置于两层实心层的两侧，在130-180℃下进行压实复合，最后将耐磨层通过传输设备置于彩膜层的表面，在130-180℃下进行压实复合，形成板材；
(5)裁剪：对板材进行冷却，裁剪。
其中，定型复合的过程中，首先需要对成型的实心层和发泡层进行冷却压平，这是因为中间层是发泡层，虽然挤出模具后就已经形成三层共挤层了，但是中间层由于是发泡层，出料后的中间层会出现波浪的形状，同时发泡层两侧的实心层也会随着发泡层出现波浪的形状，因此先用定型装置瞬间冷却压平，可以使得板材的共挤层更为平坦，有利于保证产品的质量。冷却压平后进入成型机，进行边定型边复合的过程，由于刚开始如果温度太高会出现二次发泡的现象，所以先低温冷却一段时间成型后再加温复合。成型机温度由低到高，随着板材的输送，前面的辊子温度较低，后面的辊子温度较高，一般情况下，前面的辊子温度为40-80℃，后面的辊子温度为100-160℃，当达到复合温度时，通过别的输送设备，将其他复合层输送至成型机，与共挤层进行复合。
复合的过程根据产品的需要进行调整，可以是先复合防滑层，再复合彩膜层，也可以是先复合彩膜层，再复合防滑层，或者两者同时复合。
当双面都需要彩膜层的情况下，可以将防滑层替换为彩膜层。
彩膜层的表面需要复合耐磨层，即通过传输设备将耐磨层置于彩膜层的表面，在130-180℃下进行压实复合，形成板材。
当不需要彩膜层时，也可以对彩膜层进行省略。
当不需要防滑层时，也可以对防滑层进行省略。
作为一种优选的实施例，耐磨层或/和彩膜层复合后，分别在130-180℃下，对彩膜层的表面或/和耐磨层的表面进行压纹。压纹的过程可选可不选，根据产品需求进行定制，当不需要压纹时，可以将花辊换为光辊即可。
本申请上述板材的生产方法，混料熔融挤出后在成型机上一步定型、复合，实现了板材生产的一步成型。
传统的木塑板材的加工过程为挤出基材—砂光表面—涂胶—贴合—堆码—冷压—养生—分切—开槽—检测包装—打托—入库装箱。
本申请一步法加工过程为一步成型—养生—分切—开槽—检测包装—打托—入库装箱。
其中，所述养生为将成型后的板材放置一段时间，使其适应周围环境的湿度。养生后的板材进行下一步工序时不容易变形。
本申请的一步法生产工艺省掉五个工序的同时也省掉了以下的投入：
1、省掉了五个工序的设备的同时也省掉的设备占地面积的空间；
2、省掉了设备就省掉了钱和电费；
3、省掉了大量的人工(五个环节都需要工人)；
4、省掉了材料，比如说贴合前需要用胶水；同时胶水的成分不利于身体健康；
5、不需要砂光就没有粉尘，更加环保。
本产品具有非常优越的特点：
1、板材质地柔软，弹性很好，在重物冲击下有着良好的弹性恢复，能大大减少人员的滑到摔伤，同时对重物的冲击破坏也有良好的弹性恢复，不会造成损坏；
2、绿色环保、无毒无害、无放射性污染、属绿色环保产品，可资源回收利用；
3、板材有遇水即涩的特性，同时都做了防滑处理(耐磨层花纹)；
4、安全性高、绝缘、阻燃、耐腐蚀、耐酸碱、表面无异状、离开明火能自熄；
5、防水、防潮、遇水不变形；
6、板材的吸音可达20分贝，所以在需要安静的环境如医院病房、图书馆、报告厅等地选用本申请的板材，就不用再为高跟鞋的响声而烦恼；
7、板材可以加工成众多的颜色和花纹，使用者的花纹的可选择范围更广泛，可以实现个性化定制；
8、施工安装简便；
9、超高性价比：比专业木地板价格便宜很多，但性能更卓越；
10、成品密度可在0.9T/m3-1.2T/m3内任意控制；
11、收缩率比传统的木塑板材低一到二倍之间；
12、基材部分可实现模内多层复合，再像SPC(石塑)地板一样，将彩膜和耐磨层材料同步复合成型，产品下线后直接开槽UV等即可成品销售；
13、大幅度的降低了设备成本、材料成本、人工成本及多步法成本，自动化程度高；
14、产量高，重量轻，涨缩率低，不开裂，不变形，零污染。
实施例1
按照表1准备原材料，表1为一个批次的用量。
表1 实施例1的配方成分表
Figure PCTCN2017097793-appb-000001
其中，青岛阳光嘉恒国际贸易有限公司德国巴斯夫在中国的唯一总代理。
OA6(氧化聚乙烯蜡)是一种高密度氧化聚乙烯蜡，前期起促进塑化、增大电流作用， 后期起润滑作用。它的内润滑效果大于外润滑。
PE蜡为PVC加工的外润滑剂，调节塑化时间，增加制品表面光洁度，过少则塑化时间短，粘附严重，热稳定性差；过量则出现析出，模具内结垢。
60为内润滑剂，调节PVC物料内滑动性,减少熔体内摩擦，降低电流，协助物料均匀塑化，使用过量则破坏熔体黏度。
按照表1进行材料的准备，进行地板的生产，具体步骤如下：
(1)混料：将用于生产板材发泡层的组合物和用于生产板材实心层的组合物分别进行混料，先进行热混，当温度到达105-110℃时，再冷却搅拌；
其中，实心层物料搅拌的同时将DOP(因为是液体)慢慢的倒入旋转的搅拌机内，这样搅拌的比较均匀；
(2)熔融：当物料温度降低至30-35℃时，将两种混合后的物料分别上料至挤出机的料斗，两种物料分别经事先预热至150-160℃的挤出机进行加热挤压成为熔体；
(3)分配成型：两种物料的熔体按照中间层为发泡层，发泡层的两侧为实心层的形式经过分配器进入160-180℃的模具腔内进行成型；
(4)定型复合：首先将成型的实心层和发泡层一起在20-25℃下冷却压平，随后温度逐渐升高；然后将需要复合的彩膜层和防滑层分别通过传输设备置于两层实心层的两侧，在130-150℃下进行压实复合，最后将耐磨层通过传输设备置于彩膜层的表面，在130-150℃下进行压实复合，形成板材；防滑层和彩膜层复合后，分别在130-150℃下，对彩膜层的表面或/和防滑层的表面进行压纹；
(5)裁剪：对板材进行冷却，裁剪。
实施例2
按照表2准备原材料，表2为一个批次的用量。
表2 实施例2的配方成分表
Figure PCTCN2017097793-appb-000002
Figure PCTCN2017097793-appb-000003
按照表2进行材料的准备，进行地板的生产，具体步骤如下：
(1)混料：将用于生产板材发泡层的组合物和用于生产板材实心层的组合物分别进行混料，先进行热混，当温度到达110-115℃时，再冷却搅拌；
(2)熔融：当物料温度降低至30-40℃时，将两种混合后的物料分别上料至挤出机的料斗，两种物料分别经事先预热至160-170℃的挤出机进行加热挤压成为熔体；
(3)分配成型：两种物料的熔体按照中间层为发泡层，发泡层的两侧为实心层的形式经过分配器进入165-170℃的模具腔内进行成型；
(4)定型复合：首先将成型的实心层和发泡层一起在35-40℃下冷却压平，随后温度逐渐升高；然后将需要复合的彩膜层或/和防滑层分别通过传输设备置于两层实心层的两侧，在 150-160℃下进行压实复合，最后将耐磨层通过传输设备置于彩膜层的表面，在150-160℃下进行压实复合，形成板材；防滑层和彩膜层复合后，分别在150-160℃下，对彩膜层的表面或/和防滑层的表面进行压纹；
(5)裁剪：对板材进行冷却，裁剪。
实施例3
按照表3准备原材料，表3为一个批次的用量。
表3 实施例3的配方成分表
Figure PCTCN2017097793-appb-000004
Figure PCTCN2017097793-appb-000005
按照表3进行材料的准备，进行地板的生产，具体步骤如下：
(1)混料：将用于生产板材发泡层的组合物和用于生产板材实心层的组合物分别进行混料，先进行热混，当温度到达115-120℃时，再冷却搅拌；
(2)熔融：当物料温度降低至35-40℃时，将两种混合后的物料分别上料至挤出机的料斗，两种物料分别经事先预热至170-180℃的挤出机进行加热挤压成为熔体；
(3)分配成型：两种物料的熔体按照中间层为发泡层，发泡层的两侧为实心层的形式经过分配器进入170-180℃的模具腔内进行成型；
(4)定型复合：首先将成型的实心层和发泡层一起在40-50℃下冷却压平，随后温度逐渐升高；然后将需要复合的彩膜层或/和防滑层分别通过传输设备置于两层实心层的两侧，在170-180℃下进行压实复合，最后将耐磨层通过传输设备置于彩膜层的表面，在170-180℃下进行压实复合，形成板材；防滑层和彩膜层复合后，分别在170-180℃下，对彩膜层的表面或/和防滑层的表面进行压纹；
(5)裁剪：对板材进行冷却，裁剪。
实施例4
按照表4准备原材料，表4为一个批次的用量。
表4 实施例4的配方成分表
Figure PCTCN2017097793-appb-000006
Figure PCTCN2017097793-appb-000007
按照表4进行材料的准备，进行地板的生产，具体步骤如下：
(1)混料：将用于生产板材发泡层的组合物和用于生产板材实心层的组合物分别进行混料，先进行热混，当温度到达105-120℃时，再冷却搅拌；
(2)熔融：当物料温度降低至30-40℃时，将两种混合后的物料分别上料至挤出机的料斗，两种物料分别经事先预热至150-180℃的挤出机进行加热挤压成为熔体；
(3)分配成型：两种物料的熔体按照中间层为发泡层，发泡层的两侧为实心层的形式经过分配器进入160-180℃的模具腔内进行成型；
(4)定型复合：首先将成型的实心层和发泡层一起在20-50℃下冷却压平，随后温度逐渐升高；然后将需要复合的彩膜层和防滑层分别通过传输设备置于两层实心层的两侧，在130-180℃下进行压实复合，最后将耐磨层通过传输设备置于彩膜层的表面，在130-180℃下进行压实复合，形成板材；防滑层和彩膜层复合后，分别在130-180℃下，对彩膜层的表面或/和防滑层的表面进行压纹。
(5)裁剪：对板材进行冷却，裁剪。
实施例5
按照表5准备原材料。
表5 实施例5的配方成分表
Figure PCTCN2017097793-appb-000008
按照表5进行材料的准备，进行非地板用板材的生产，具体步骤如下：
(1)混料：将用于生产板材发泡层的组合物和用于生产板材实心层的组合物分别进行混料，先进行热混，当温度到达105-120℃时，再冷却搅拌；
(2)熔融：当物料温度降低至30-40℃时，将两种混合后的物料分别上料至挤出机的料 斗，两种物料分别经事先预热至150-180℃的挤出机进行加热挤压成为熔体；
(3)分配成型：两种物料的熔体按照中间层为发泡层，发泡层的两侧为实心层的形式经过分配器进入160-180℃的模具腔内进行成型；
(4)定型复合：首先将成型的实心层和发泡层一起在20-50℃下冷却压平，随后温度逐渐升高；然后将需要复合的彩膜层通过传输设备置于两层实心层的两侧，在130-180℃下进行压实复合，最后将耐磨层通过传输设备置于彩膜层的表面，在130-180℃下进行压实复合，形成板材；彩膜层复合后，分别在130-180℃下，对彩膜层的表面或/和防滑层的表面进行压纹；
(5)裁剪：对板材进行冷却，裁剪。
对于实施例1-5生产的板材与传统板材进行性能测试，测试结果如表6所示。
表6 本申请生产的板材与传统板材各性能指标对比表
Figure PCTCN2017097793-appb-000009
通过表6可以知道，本申请生产得到的板材各项指标均优于传统板材。

Claims (20)

  1. 一种用于生产板材发泡层的组合物，其特征在于：包括主要成分和辅助成分，所述的主要成分由聚氯乙烯和碳酸钙组成，所述的辅助成分包括调节剂、稳定剂、润滑剂、发泡剂；按照重量份数计，所述的聚氯乙烯为75份，所述的碳酸钙为75-80份，所述的调节剂为6-8份，所述的稳定剂为3-5份，所述的润滑剂为0.7-1.4份；所述的发泡剂为0.2-0.7份。
  2. 根据权利要求1所述的组合物，其特征在于：还包括回料，所述的回料占发泡层组合物总质量的5-25％。
  3. 根据权利要求1所述的组合物，其特征在于：所述的润滑剂包括内润滑剂和外润滑剂，所述的内润滑剂和外润滑剂的质量比为2:1-3:1。
  4. 根据权利要求3所述的组合物，其特征在于：所述的内润滑剂为硬脂酸、多元醇硬脂肪酸和氧化聚乙烯蜡中的一种或多种；所述的外润滑剂为聚乙烯蜡。
  5. 根据权利要求3所述的组合物，其特征在于：所述的发泡剂包括白发泡剂和黄发泡剂，所述的白发泡剂和黄发泡剂的质量比为1:1-3:7。
  6. 根据权利要求3所述的组合物，其特征在于：所述的发泡剂包括白发泡剂和黄发泡剂，所述的白发泡剂和黄发泡剂的质量比为1:1-3:1。
  7. 一种板材，其特征在于：包含有如权利要求1-5任意一项所述的组合物。
  8. 根据权利要求7所述的板材，其特征在于：包括位于中间层的发泡层(4)和位于所述发泡层(4)的两侧并与所述发泡层(4)一体式挤出的实心层(3)。
  9. 根据权利要求8所述的板材，其特征在于：所述发泡层(4)一侧的实心层(3)的表面设有防滑层(5)。
  10. 根据权利要求9所述的板材，其特征在于：所述发泡层(4)一侧的实心层(3)的表面设有彩膜层(2)。
  11. 根据权利要求10所述的板材，其特征在于：所述彩膜层(2)的表面设有耐磨层(1)。
  12. 根据权利要求11所述的板材，其特征在于：所述实心层分为上实心层和下实心层，其中，上实心层和下实心层的厚度分别为1-1.5mm和0.3-0.5mm；所述发泡层的厚度为2.5-3.5mm；所述防滑层的厚度为0.15-0.3mm；所述耐磨层的厚度为0.15-0.5mm；所述彩膜层的厚度为0.07-0.08mm。
  13. 根据权利要求10所述的板材，其特征在于：用于生产板材实心层的组合物，包括主 要成分和辅助成分，所述的主要成分由聚氯乙烯和碳酸钙组成，所述的辅助成分包括调节剂、稳定剂、润滑剂；按重量份数计，所述的聚氯乙烯为50份，所述的碳酸钙为50-55份，所述的调节剂为2-7份，所述的稳定剂为2-4份、所述的润滑剂为0.5-1.1份。
  14. 根据权利要求13所述的板材，其特征在于：还包括增塑剂，所述增塑剂占实心层组合物总质量的1-8％。
  15. 根据权利要求14所述的板材，其特征在于：所述的增塑剂为邻苯二甲酸二辛酯或者环氧大豆油。
  16. 根据权利要求14所述的板材，其特征在于：所述的增塑剂为邻苯二甲酸二辛酯、环氧大豆油或对苯二甲酸二辛酯。
  17. 根据权利要求13所述的组合物，其特征在于：所述的润滑剂包括内润滑剂和外润滑剂，所述的内润滑剂和外润滑剂的质量比为2:1-3:1。
  18. 根据权利要求17所述的组合物，其特征在于：所述的内润滑剂为硬脂酸、多元醇硬脂肪酸和氧化聚乙烯蜡中的一种或多种；所述的外润滑剂为聚乙烯蜡。
  19. 一种生产如权利要求7-18任意一项所述的板材的方法，其特征在于：包括如下步骤：
    (1)混料：将用于生产板材发泡层的组合物和用于生产板材实心层的组合物分别进行混料，先进行热混，当温度到达105-120℃时，再冷却搅拌；
    (2)熔融：当物料温度降低至30-40℃时，将两种混合后的物料分别上料至挤出机的料斗，两种物料分别经事先预热至150-180℃的挤出机进行加热挤压成为熔体；
    (3)分配成型：两种物料的熔体按照中间层为发泡层，发泡层的两侧为实心层的形式经过分配器进入160-180℃的模具腔内进行成型；
    (4)定型复合：首先将成型的实心层和发泡层一起在20-50℃下冷却压平，随后温度逐渐升高；然后将需要复合的耐磨层或/和防滑层分别通过传输设备置于两层实心层的两侧，在130-180℃下进行压实复合，最后将耐磨层通过传输设备置于彩膜层的表面，在130-180℃下进行压实复合，形成板材；
    (5)裁剪：对板材进行冷却，裁剪。
  20. 根据权利要求19所述的生产板材的方法，其特征在于：所述的防滑层或/和彩膜层复合后，分别在130-180℃下，对彩膜层的表面或/和防滑层的表面进行压纹。
PCT/CN2017/097793 2017-07-17 2017-08-17 用于生产板材发泡层的组合物及包含此组合物的板材及其生产方法 WO2018113325A1 (zh)

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