Wood-plastic floor and preparation method thereof

Abstract

The invention relates to the field of wood-plastic floors, and particularly discloses a wood-plastic floor and a preparation method thereof.The wood-plastic floor comprises a surface layer, a middle layer and a bottom layer which are sequentially arranged from top to bottom, and the surface layer comprises high-density polyethylene, glass fibers, a reinforcing agent, an anti-scraping agent and an additive; the middle layer comprises bamboo and wood fibers, bio-based resin, diatomite, a mothproofing agent, a heat stabilizer, an adsorbent and a flexibilizer; the bottom layer comprises plastic resin, diatomite, composite mineral particles, magnetic particles, a flame retardant and a filler; the wood-plastic floor is prepared by co-extruding a plurality of layers of composite materials, so that the mothproof property, the moisture resistance, the deformation resistance and the wear resistance of the wood-plastic floor are improved, the wood-plastic floor has environmental protection property and sustainability, meets the requirements of sustainable development, and greatly improves the comprehensive performance of the wood-plastic floor.

Description

Technical Field

[0001] The invention relates to the field of wood plastic flooring, in particular to a wood plastic flooring and a preparation method thereof. Background Art

[0002] Wood-Plastic Composite (WPC) is a composite material made of wood fiber and plastic as the main raw materials, which is formed by special processing and is widely used in flooring, gardening, building decoration and other industries. However, traditional wood-plastic flooring has problems such as water absorption expansion, deformation and poor insect resistance due to its influence on factors such as humid environment, moth infestation and high temperature changes, which limits its application range. In order to improve these problems and improve the comprehensive performance of wood-plastic flooring, the present application proposes a wood-plastic flooring and a preparation method thereof. Summary of the invention

[0003] In view of the existing problems, the present invention provides a wood plastic floor and a preparation method thereof, which can effectively solve the problems raised in the background technology.

[0004] To solve the above problems, the present invention adopts the following technical solutions:

[0005] A wood plastic floor comprises a surface layer, a middle layer and a bottom layer arranged in sequence from top to bottom, wherein:

[0006] The surface layer comprises the following raw materials by weight: 50-70 parts of high-density polyethylene, 5-15 parts of glass fiber, 3-7 parts of reinforcing agent, 3-6 parts of anti-scratch agent and 15-25 parts of additives;

[0007] The middle layer comprises the following raw materials by weight: 40-60 parts of bamboo fiber, 20-40 parts of bio-based resin, 5-15 parts of diatomaceous earth, 2-8 parts of mothproofing agent, 1-5 parts of heat stabilizer, 3-15 parts of adsorbent and 1-3 parts of toughening agent;

[0008] The bottom layer comprises the following raw materials in parts by weight: 40-60 parts of plastic resin, 10-20 parts of diatomaceous earth, 5-15 parts of composite mineral particles, 5-15 parts of magnetic particles, 2-5 parts of flame retardant and 10-30 parts of filler.

[0009] As a further solution of the present invention: the additives of the surface layer include titanium dioxide particles and silicon dioxide nanoparticles, wherein the titanium dioxide particles are 1-5 parts and the silicon dioxide nanoparticles are 5-20 parts.

[0010] As a further solution of the present invention: the surface layer further includes a photocatalyst coating, the photocatalyst coating is coated on the upper surface of the surface layer, and the thickness of the photocatalyst coating is 0.01 mm to 0.1 mm.

[0011] As a further solution of the present invention: the adsorbent in the middle layer includes bamboo charcoal powder and activated carbon particles, wherein the bamboo charcoal powder is 2-10 parts and the activated carbon particles are 1-5 parts.

[0012] As a further solution of the present invention: the composite mineral particles of the bottom layer include bentonite and zeolite, and the ratio of bentonite to zeolite is 1:1-5.

[0013] As a further solution of the present invention: the bottom layer also includes 2-8 parts of water absorption inhibitor.

[0014] As a further solution of the present invention: the water absorption inhibitor is calcium chloride or silica gel.

[0015] As a further solution of the present invention: the magnetic particles are ferromagnetic powder.

[0016] As a further solution of the present invention: the filler is stone powder.

[0017] A method for preparing a wood plastic floor comprises the following steps:

[0018] S1. Add the raw materials of the surface layer, the middle layer and the bottom layer in different mixing equipment according to the weight ratio, mix and stir evenly at a temperature of 100-180° C. to obtain a surface layer mixture, a middle layer mixture and a bottom layer mixture respectively;

[0019] S2, the surface layer mixture, the middle layer mixture and the bottom layer mixture are respectively extruded by a rod extruder, and the surface layer, the middle layer and the bottom layer are extruded and formed by a multi-layer co-extrusion die to obtain a wood plastic floor blank;

[0020] S3, after the wood plastic flooring blank is cooled and solidified, it is cut according to the size of the flooring to obtain the wood plastic flooring.

[0021] Compared with the prior art, the beneficial effects of the present invention are as follows: the present invention effectively prevents wood fiber from being attacked by moths by adding mothproofing agents to the middle layer, thereby improving the mothproofing performance; the material ratio of the middle layer and the bottom layer enhances the stability of the floor, thereby avoiding deformation problems under different temperature and humidity conditions; the addition of heat stabilizers and toughening agents enables the floor to maintain its shape even in extreme environments, thereby avoiding the effects of thermal expansion and contraction on the floor; the diatomaceous earth and composite mineral particles added to the bottom layer enhance the moisture-proof effect of the floor, thereby preventing moisture from penetrating into the wood fiber layer, thereby avoiding expansion, deformation or deterioration of the wood-plastic floor caused by a humid environment; the glass fiber, reinforcing agent and anti-scratch agent added to the surface layer enhance the wear resistance of the wood-plastic floor, thereby preventing the surface from being scratched or worn; the main materials are widely available and environmentally friendly, thereby meeting the needs of modern sustainable development.

[0022] The invention adopts the co-extrusion preparation of multi-layer composite materials, improves the moth resistance, moisture resistance, deformation resistance and wear resistance of the wood plastic floor, is environmentally friendly and sustainable, meets the requirements of sustainable development, and greatly improves the comprehensive performance of the wood plastic floor. DETAILED DESCRIPTION

[0023] The following will be combined with the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.

[0024] The present embodiment provides a wood plastic floor, which includes a surface layer, a middle layer and a bottom layer arranged in sequence from top to bottom. The surface layer is the outermost layer of the wood plastic floor, with a thickness of 0.3mm-1mm, and mainly plays a protective role. The middle layer is the structural layer of the wood plastic floor, with a thickness of 3mm-8mm, and is mainly responsible for supporting strength and anti-deformation ability, ensuring that the floor is not prone to bending and cracking under long-term use. The middle layer also takes into account the weight and stability of the material to ensure that the floor exhibits good mechanical properties in daily use. The bottom layer has a thickness of 1mm-3mm. The bottom layer mainly functions to prevent moisture and improve the overall stability of the wood plastic floor, can effectively prevent moisture from entering, reduce the expansion and deformation of the floor in a humid environment, and increase the moisture resistance and compression resistance of the floor, wherein:

[0025] The surface layer comprises the following raw materials by weight: 50-70 parts of high-density polyethylene, 5-15 parts of glass fiber, 3-7 parts of reinforcing agent, 3-6 parts of anti-scratch agent and 15-25 parts of additives;

[0026] The middle layer includes the following raw materials by weight: 40-60 parts of bamboo fiber, 20-40 parts of bio-based resin, 5-15 parts of diatomaceous earth, 2-8 parts of mothproofing agent, 1-5 parts of heat stabilizer, 3-15 parts of adsorbent and 1-3 parts of toughening agent;

[0027] The bottom layer comprises the following raw materials in parts by weight: 40-60 parts of plastic resin, 10-20 parts of diatomaceous earth, 5-15 parts of composite mineral particles, 5-15 parts of magnetic particles, 2-5 parts of flame retardant and 10-30 parts of filler.

[0028] Example 1

[0029] A wood plastic floor comprises a surface layer, a middle layer and a bottom layer arranged in sequence from top to bottom, wherein:

[0030] The surface layer comprises the following raw materials by weight: 60 parts of high-density polyethylene, 10 parts of glass fiber, 5 parts of reinforcing agent, 5 parts of anti-scratch agent and 20 parts of additives;

[0031] The middle layer includes the following raw materials by weight: 50 parts of bamboo fiber, 20 parts of bio-based resin, 10 parts of diatomaceous earth, 5 parts of mothproofing agent, 3 parts of heat stabilizer, 10 parts of adsorbent and 2 parts of toughening agent;

[0032] The bottom layer comprises the following raw materials in parts by weight: 50 parts of plastic resin, 15 parts of diatomaceous earth, 10 parts of composite mineral particles, 10 parts of magnetic particles, 3 parts of flame retardant and 12 parts of filler.

[0033] The high-density polyethylene in the surface layer has excellent weather resistance, chemical corrosion resistance and UV resistance. High-density polyethylene can effectively delay the aging of the floor surface and prevent the surface from fading, cracking or other damage due to ultraviolet radiation. Glass fiber, as a reinforcing material, can improve the impact resistance, hardness and wear resistance of the surface layer, and enhance the surface scratch resistance of the floor, making it less susceptible to damage from external forces in daily use. The reinforcing agent is ultrafine calcium carbonate. Ultrafine calcium carbonate is used as a filling material in the surface layer to improve the surface hardness, wear resistance and scratch resistance of the material, making the floor surface harder and enhancing its durability. The anti-scratch agent is polyamide powder. Polyamide powder has strong anti-friction properties and can increase the scratch resistance of the surface layer, especially in places with high frequency of use (such as homes and commercial places), which can effectively extend the service life of the floor.

[0034] The middle layer uses bamboo fiber as the main component, which provides the strength and rigidity of the wood-plastic floor. Bamboo fiber can effectively enhance the load-bearing capacity and bending resistance of the floor, while reducing the amount of plastic substrate, improving environmental protection, and using bio-based resin to provide adhesion and structural support to ensure the stability of the floor. Bio-based resin uses PLA resin or PBS resin. Bio-based resin is a resin made from renewable plant resources (such as vegetable oil, starch, etc.). Bio-based resin has the characteristics of being degradable and environmentally friendly. It not only plays the role of bonding and molding, but also improves the weather resistance, toughness and environmental protection performance of the floor. Diatomaceous earth is a natural inorganic material with excellent water absorption and heat resistance. It can effectively absorb moisture in bamboo fiber and reduce the water absorption and expansion of the floor in a humid environment. Diatomaceous earth can also enhance the durability of the floor and improve its anti-deformation performance. The mothproofing agent uses natural plant extracts, such as camphor or peppermint oil. The mothproofing agent is used in the wood fiber part of the middle layer, which can effectively prevent the wood fiber from being attacked by moths. Natural plant extracts not only have a killing effect on moths, but are also environmentally friendly and do not cause harm to the human body and the environment. Thermal stabilizers can improve the thermal stability of the middle layer material under high temperature conditions, prevent thermal deformation or aging of the material in high temperature environments, and thus enhance the deformation resistance of the wood plastic floor. Toughening agents are polymer modifiers that can improve the toughness of the material, making the floor have better impact resistance and fracture resistance, ensuring that the floor is not prone to brittle cracks or fractures during long-term use.

[0035] The composite mineral particles of the bottom layer include bentonite and zeolite, and the ratio of bentonite to zeolite is 1:1-5. The composite particles of zeolite and bentonite can not only further improve the water resistance, but also help control the adsorption and release of water. The composite mineral particles improve the waterproof performance and anti-moisture stability of the bottom layer, and can effectively reduce the expansion or contraction caused by moisture. The magnetic particles are ferromagnetic powders. The added magnetic particles can provide additional functionality for the floor, such as preventing water vapor accumulation, or providing electromagnetic shielding functions for specific industries to meet the needs of more segmented markets. The flame retardant uses an environmentally friendly flame retardant, which can improve the fire resistance of the wood plastic floor and is particularly suitable for use in high fire risk environments, such as commercial places and kitchens. The filler is stone powder, and other mineral powders can also be used to increase the density and hardness of the bottom layer, reduce costs, and improve compression resistance.

[0036] Example 2

[0037] In this example, the additives of the surface layer include titanium dioxide particles and silica nanoparticles, wherein the titanium dioxide particles are 1-5 parts and the silica nanoparticles are 5-20 parts. Titanium dioxide, as a highly efficient UV absorber, can further enhance the UV resistance of the surface layer, and its chemical stability is very good, which helps to improve the aging resistance of the surface layer. The silica nanoparticles can enhance the scratch resistance, hardness and wear resistance of the surface layer, and have strong waterproof and UV resistance functions. The nanoparticles can improve the surface strength and reduce surface wear.

[0038] Example 3

[0039] In this example, a layer of photocatalyst coating is also coated on the upper surface of the surface layer, and the photocatalyst coating is TiO2 photocatalyst, and the thickness of the photocatalyst coating is 0.01mm to 0.1mm. The photocatalyst coating can not only enhance the resistance to ultraviolet rays, but also has certain anti-pollution and anti-mold growth functions, improve the self-cleaning ability of the floor, and improve the durability of the surface layer.

[0040] Example 4

[0041] The adsorbents in the middle layer include bamboo charcoal powder and activated carbon particles, of which bamboo charcoal powder is 2-10 parts and activated carbon particles are 1-5 parts. Bamboo charcoal powder can not only improve the antibacterial and deodorizing ability of the middle layer, but also effectively absorb moisture in the air and enhance the moisture resistance of the floor. The porous structure of bamboo charcoal powder also helps to enhance the mechanical properties of the board. As a highly adsorbent material, activated carbon particles can effectively absorb moisture and enhance moisture resistance, reduce the risk of wood absorbing water and swelling, and it can also effectively inhibit the growth of mold and bacteria. Bamboo charcoal powder and activated carbon increase the hygroscopicity, antibacterial and mildew resistance of the middle layer, which makes the wood-plastic floor perform better in humid environments, especially in humid areas such as basements, kitchens, and bathrooms.

[0042] Example 5

[0043] In this example, 2-8 parts of water absorption inhibitor are added to the base layer. The water absorption inhibitor is calcium chloride or silica gel. The water absorption inhibitor can reduce water absorption, enhance moisture resistance, prevent the wood plastic floor from swelling, deformation or mildew due to water absorption, and can significantly improve the performance of the wood plastic floor in a humid environment, thereby improving the durability and stability of the wood plastic floor.

[0044] Example 6

[0045] This embodiment provides a method for preparing a wood plastic floor. The method is based on the ingredients of each layer of the above embodiment 1 and specifically includes the following steps:

[0046] S1. Add the raw materials of the surface layer, the middle layer and the bottom layer in different mixing equipment according to the weight ratio, mix and stir evenly at a temperature of 100-180° C. to obtain a surface layer mixture, a middle layer mixture and a bottom layer mixture respectively;

[0047] S2, the surface layer mixture, the middle layer mixture and the bottom layer mixture are respectively extruded by a rod extruder, and the surface layer, the middle layer and the bottom layer are extruded and formed by a multi-layer co-extrusion die to obtain a wood plastic floor blank;

[0048] S3, after the wood plastic flooring blank is cooled and solidified, it is cut according to the size of the flooring to obtain the wood plastic flooring.

[0049] The prepared wood plastic floor is subjected to quality inspection and testing, including:

[0050] Physical properties testing

[0051] 1. Dimensional stability test:

[0052] Expansion and shrinkage test: In high temperature and humid environment, the expansion and shrinkage of wood plastic flooring should be strictly controlled. The changes in length, width and thickness can be measured after the sample is soaked in standard water for 24 hours.

[0053] Thermal deformation temperature test: Wood plastic flooring should have good stability under high temperature conditions. Through thermal deformation test, its performance in high temperature environment can be evaluated.

[0054] 2. Tensile strength and bending strength test:

[0055] The tensile strength, bending strength and compression strength of the floor are tested to ensure that the floor has sufficient load-bearing capacity in actual use. This is done in accordance with standards such as ISO 178 (bending strength test) and ISO 527 (tensile strength test).

[0056] 3. Wear resistance test:

[0057] Carry out abrasion resistance test according to ISO 5470-1 or ASTM D4060 to test the wear degree of the surface of the wood plastic floor under friction to ensure that its wear resistance meets the industry standard.

[0058] 4. Anti-scratch test:

[0059] Use standard hardness test tools (such as Mohs hardness tester or steel ball test) to evaluate the scratch resistance of the wood plastic floor surface. Test whether scratches appear on the surface by rubbing with a certain load and a certain time.

[0060] 5. Impact resistance test:

[0061] The impact resistance of wood plastic flooring is tested according to ISO 180 or ASTM D256. The impact resistance of the floor is evaluated by applying a certain weight to the surface of the floor.

[0062] Chemical performance testing

[0063] 1. Anti-ultraviolet performance:

[0064] Use Q-Sun (ultraviolet accelerated aging test) or ASTM G154 to test the UV resistance of WPC flooring. The UV accelerated aging test can simulate long-term exposure to sunlight to evaluate the color changes and physical property changes of WPC flooring.

[0065] 2. Waterproof performance:

[0066] Water absorption test: By measuring the mass change of the floor sample after soaking in water, its water absorption rate is tested. The water absorption rate of the wood plastic floor should be less than 10%.

[0067] Waterproof performance test: After placing the floor sample in water for a certain period of time, check whether there is any expansion, deformation or surface peeling.

[0068] 3. Flame retardancy test:

[0069] Test the flame retardancy of wood plastic flooring according to UL 94 or ISO 11925-2. In particular, the flame retardant used in the base layer needs to ensure that it meets the relevant fire safety standards.

[0070] 4. Detection of harmful substances:

[0071] In accordance with environmental protection standards, the floor is tested for harmful substances to ensure that it does not contain toxic volatile organic compounds (VOCs), formaldehyde, heavy metals, etc., and meets E1 level (environmental protection level) or other standards.

[0072] Through the above physical property test and chemical property test, the physical property test and chemical property test of the wood plastic floor of the present invention both meet the qualified standards, the quality is qualified, and the expected function is achieved.

[0073] Compared with the existing wood plastic flooring, the present invention has outstanding advantages:

[0074] 1. Moisture-proof and waterproof: Through the co-extrusion preparation of multi-layer composite materials, combined with the use of natural materials such as bamboo charcoal powder and activated carbon particles, the moisture-proof performance of the wood plastic floor is greatly improved;

[0075] 2. Anti-ultraviolet and anti-aging: The photocatalyst coating and silica nanoparticles on the surface give the floor strong anti-ultraviolet, wear-resistant and self-cleaning capabilities, extending the service life of the floor;

[0076] 3. Anti-insect and antibacterial: The addition of bamboo charcoal and activated carbon particles makes the wood plastic floor have natural anti-insect and antibacterial properties, suitable for use in humid and bacteria-breeding environments;

[0077] 4. Environmental protection and sustainability: The present invention uses bio-based resins and natural materials, which meet green environmental protection requirements and have a lower carbon footprint;

[0078] 5. Durability and anti-deformation: By adding toughening agents and thermal stabilizers, the deformation resistance of the floor under extreme temperatures is improved, making it suitable for various climatic conditions.

[0079] It should be noted that, in this article, relational terms such as first and second, etc. are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any actual relationship or order between these entities or operations. Moreover, the terms "include", "comprises" or any other variations thereof are intended to cover non-exclusive inclusion, so that a process, method, article or apparatus that includes a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or apparatus.

[0080] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A wood plastic floor, characterized in that: It includes a surface layer, a middle layer and a bottom layer arranged in sequence from top to bottom, wherein: The surface layer comprises the following raw materials by weight: 50-70 parts of high-density polyethylene, 5-15 parts of glass fiber, 3-7 parts of reinforcing agent, 3-6 parts of anti-scratch agent and 15-25 parts of additives; The middle layer comprises the following raw materials by weight: 40-60 parts of bamboo fiber, 20-40 parts of bio-based resin, 5-15 parts of diatomaceous earth, 2-8 parts of mothproofing agent, 1-5 parts of heat stabilizer, 3-15 parts of adsorbent and 1-3 parts of toughening agent; The bottom layer comprises the following raw materials in parts by weight: 40-60 parts of plastic resin, 10-20 parts of diatomaceous earth, 5-15 parts of composite mineral particles, 5-15 parts of magnetic particles, 2-5 parts of flame retardant and 10-30 parts of filler.

2. A wood plastic floor according to claim 1, characterized in that: The additives of the surface layer include titanium dioxide particles and silicon dioxide nanoparticles, wherein the titanium dioxide particles are 1-5 parts and the silicon dioxide nanoparticles are 5-20 parts.

3. A wood plastic floor according to claim 1, characterized in that: The surface layer further comprises a photocatalyst coating, which is coated on the upper surface of the surface layer, and has a thickness of 0.01 mm to 0.1 mm.

4. The wood plastic flooring according to claim 1, characterized in that: The adsorbent in the middle layer includes bamboo charcoal powder and activated carbon particles, wherein the bamboo charcoal powder is 2-10 parts and the activated carbon particles are 1-5 parts.

5. The wood plastic floor according to claim 1, characterized in that: The composite mineral particles of the bottom layer include bentonite and zeolite, and the ratio of bentonite to zeolite is 1:1-5.

6. The wood plastic flooring according to claim 1, characterized in that: The bottom layer also includes 2-8 parts of water absorption inhibitor.

7. The wood plastic flooring according to claim 6, characterized in that: The water absorption inhibitor is calcium chloride or silica gel.

8. The wood plastic flooring according to claim 1, characterized in that: The magnetic particles are ferromagnetic powder.

9. The wood plastic flooring according to claim 1, characterized in that: The filler is stone powder.

10. A method for preparing the wood plastic flooring according to any one of claims 1 to 9, characterized in that: The steps include: S1. Add the raw materials of the surface layer, the middle layer and the bottom layer in different mixing equipment according to the weight ratio, mix and stir evenly at a temperature of 100-180° C. to obtain a surface layer mixture, a middle layer mixture and a bottom layer mixture respectively; S2, the surface layer mixture, the middle layer mixture and the bottom layer mixture are respectively extruded by a rod extruder, and the surface layer, the middle layer and the bottom layer are extruded and formed by a multi-layer co-extrusion die to obtain a wood plastic floor blank; S3, after the wood plastic flooring blank is cooled and solidified, it is cut according to the size of the flooring to obtain the wood plastic flooring.