Environment-friendly plastic-wood floor and preparation process thereof

Abstract

This application relates to an environmentally friendly fiber-plastic flooring and its preparation process, and is in the technical field of resource utilization of waste textiles. This application uses waste textiles as the main raw material to produce fiber-plastic flooring, accounting for 40-60%. It can directly utilize blended and miscellaneous waste textiles without the need for fine sorting, and can achieve an annual disposal of tens of thousands of tons of waste textiles with a resource utilization rate of over 95%. It effectively solves the pollution problems caused by landfilling and incineration of waste textiles, and is in line with the national circular economy and "dual carbon" strategy. Moreover, the flooring is waterproof, mildew-proof, and highly weather-resistant: the product's water absorption expansion rate is ≤0.3%, making it completely waterproof and moisture-proof, and not easy to mold or deform. It is especially suitable for balconies, outdoor courtyards, scenic spots, garden homestays, public green spaces, waterfront mountainous areas, and other humid and sun-exposed environments.

Description

Technical Field

[0001] This application relates to the technical field of resource utilization of waste textiles, and in particular to an environmentally friendly fiber-plastic flooring and its preparation process. Background Technology

[0002] With the rapid development of the textile industry and the improvement of people's living standards, the amount of waste textiles (including waste clothing, textile scraps, and waste home textiles) has increased dramatically year by year, becoming the third largest solid waste after waste plastics and waste paper. Currently, the comprehensive utilization rate of waste textiles in my country is only about 19%, and the main treatment methods are landfill and incineration. This not only occupies a large amount of land resources, but also produces harmful gases such as dioxins during the incineration process, causing serious environmental pollution and highlighting the problem of resource waste. Under the background of the dual-carbon era, landfill disposal of waste is no longer allowed, and the avoidance of incineration and the transformation to resource recycling are encouraged.

[0003] While there have been a few attempts to use waste textiles to prepare building materials in the existing technology, most of them have technical defects and cannot achieve large-scale, harmless, and high-value recycling. Moreover, at present, wood flooring and wood-plastic composite flooring are still the mainstream in the field of building materials, especially outdoor flooring.

[0004] However, traditional wood flooring has drawbacks such as being non-waterproof and prone to mold growth. It easily swells, cracks, and molds when exposed to water, with a lifespan of only 3-5 years. Traditional wood-plastic composite flooring has a water absorption expansion rate of ≥0.5%, and is still susceptible to moisture damage and deformation in high-temperature and high-humidity environments, failing to meet the needs of humid environments such as kitchens, bathrooms, and outdoor spaces. Furthermore, the production of traditional wood flooring consumes a large amount of virgin timber, which does not comply with the national "dual-carbon" strategy and the requirements for circular economy development. At the same time, traditional boards pose a formaldehyde release risk; traditional MDF and particleboard use urea-formaldehyde resin adhesives, with formaldehyde release levels generally ≥0.124 mg / m³. 3 Prolonged exposure can harm human health; although traditional wood-plastic composite flooring is relatively environmentally friendly, it uses a lot of plastic components and cannot completely solve the problem of formaldehyde release.

[0005] Therefore, addressing the shortcomings of existing flooring, especially outdoor flooring materials, in terms of waterproofing and environmental protection, developing an environmentally friendly fiber-plastic flooring with a unique formula and advanced technology, using waste textiles as the core raw material, to achieve the reduction, harmlessness, high-value recycling of waste textiles, has become an urgent technical challenge to be solved in this field. Summary of the Invention

[0006] To address the issues of traditional flooring, especially outdoor flooring, being non-waterproof and prone to mold, while simultaneously achieving efficient resource utilization of waste textiles, improving product environmental friendliness and stability, reducing production costs, and realizing a balance of environmental, economic, and social benefits, this application provides an environmentally friendly fiber-plastic flooring and its preparation process.

[0007] This application provides an environmentally friendly fiber-plastic flooring and its manufacturing process, which adopts the following technical solution: An environmentally friendly fiber-plastic flooring, wherein the raw materials of the environmentally friendly fiber-plastic flooring include, by weight: 40-60 parts of waste textile fiber particles, 20-30 parts of recycled plastic substrate, 5-10 parts of inorganic reinforcing filler, 2-5 parts of environmentally friendly composite compatibilizer, 0.3-1 parts of environmentally friendly lubricant, and 0.5-2.5 parts of environmentally friendly color masterbatch.

[0008] By adopting the above technical solution, using waste textiles as the core raw material, combined with recycled plastics and various environmentally friendly additives, the flooring meets the standards for mechanical and weather resistance properties. This achieves the reduction, harmlessness, high-value utilization, and resource utilization of waste textiles, significantly reducing raw material costs. At the same time, it eliminates the use of urea-formaldehyde resin adhesives in traditional boards, fundamentally solving the formaldehyde release problem. No heavy metals were detected, meeting the development requirements of the national circular economy and "dual-carbon" strategy, as well as the standards for green and healthy building materials.

[0009] Optionally, the waste textile fiber particles are made by crushing waste textiles, including cotton, polyester, nylon and blended waste textiles, and the blended materials can be used directly without fine sorting.

[0010] By adopting the above technical solution, blended waste textiles can be directly utilized without the need for fine sorting, which greatly reduces the pre-processing cost of waste textiles. At the same time, it realizes the unified disposal of various types of waste textiles and improves the utilization rate of waste resources.

[0011] Optionally, the recycled plastic substrate is HDPE recycled plastic, which has undergone melt modification treatment to improve the interfacial bonding force with textile fibers.

[0012] By adopting the above technical solution, the use of recycled HDPE plastic not only reduces raw material costs, but also effectively improves the interfacial bonding force with textile fibers after melt modification, avoiding product delamination and cracking problems caused by poor compatibility between fibers and plastic substrates.

[0013] Optionally, the inorganic reinforcing filler is talc or calcium carbonate (calcium sulfate) activated by a silane coupling agent, with a particle size of 100-150 mesh.

[0014] By adopting the above technical solution, inorganic fillers activated by silane coupling agents can effectively improve the hardness, compressive strength and flexural strength of products, while not introducing toxic and harmful substances, ensuring the environmental friendliness of products. The 100-150 mesh particle size can ensure that the filler is uniformly dispersed in the matrix, avoiding agglomeration that affects product performance.

[0015] Optionally, the wood grain structure of the floor is prepared using a one-time molding synchronous co-extrusion texturing technology. During the extrusion molding process, the surface of the molten substrate is coated and co-extruded online using a special mold, thus simultaneously completing the shaping of the board and the construction of the texture.

[0016] By adopting the above technical solution and using one-time molding synchronous co-extrusion texturing technology, the shaping of the board and the construction of the texture can be completed simultaneously during the extrusion molding process. Under specific temperature and pressure, the surface of the co-extruded layer can be evenly distributed in the embossed concave and convex structure, forming a natural and three-dimensional realistic wood grain effect. Moreover, the color and texture are integrated, overcoming the defects of traditional printed laminated flooring textures that are stiff and easily worn and faded. At the same time, different textures and colors can be customized by switching molds to meet diverse decorative needs.

[0017] Optionally, the floor is provided with a single locking system on both sides of the edge, the single locking system consisting of two parallel and independent grooves on both sides of the floor.

[0018] By adopting the above technical solution, the single-locking system enables the floorboards to form a double interlock with the male tenons of adjacent floorboards when they are spliced ​​laterally. Through the precise cooperation between the two female grooves and the corresponding male tenons, the lateral stability and connection strength of the spliced ​​floorboards are significantly enhanced. This effectively prevents problems such as arching and gaps caused by thermal expansion and contraction or external forces during the use of the floorboards, thereby improving the overall installation quality and service life of the floorboards.

[0019] Optionally, the floor is provided with a double locking system on both sides of the edge, the double locking system consisting of a male latch on one side of the floor and a female latch on the other side.

[0020] By adopting the above technical solutions, it is ensured that the flooring is tightly joined after splicing, with smooth and concealed seams, supporting glue-free quick installation and disassembly, which greatly improves the convenience of construction.

[0021] By adopting the above technical solutions and using an integrated dedicated production line, the entire process of automated continuous production from pretreatment of waste textiles to finished product packaging has been realized. This effectively solves the problems of uneven fiber dispersion and loose product structure in waste textiles, significantly improves production efficiency, and ensures the performance stability of the products.

[0022] A manufacturing process for an environmentally friendly fiberglass flooring includes: S1. Pre-treatment of waste textiles: Waste textiles are directly fed into a crusher for crushing and granulation, without the need for sorting; S2. High-precision mixing: The pretreated material and the remaining raw materials are put into a mixing mixer and mixed at low speed for 10-20 minutes to obtain a uniform mixture. S3. Preparation and integrated molding of fiber-plastic composite materials: The mixture is fed into an internal mixing equipment for melt plasticization, internal mixing and fusion, and then precisely molded by an extrusion molding equipment; S4. Post-processing: The molded flooring (1) undergoes surface modification treatment, online testing, and graded packaging.

[0023] By adopting the above technical solution, the temperature and rotation speed parameters can be adapted to the characteristics of waste textile fibers, avoiding fiber carbonization and plastic decomposition caused by high temperature. At the same time, the high-intensity shearing and kneading of the internal mixer promotes the interfacial fusion of fibers and plastic substrates, so that the fibers are evenly dispersed in the melt, improving the plasticization quality of the material and the density of the product, and ensuring the high performance of the flooring.

[0024] Optionally, in the preparation stage and integrated molding of the fiber-plastic composite material, a twin-screw extruder is used in the melt plasticizing step, and the temperature of each section of the twin-screw extruder is controlled: 190-230℃ for the feeding section, 200-250℃ for the melting section, 190-220℃ for the conveying section, and 180-200℃ for the die head section; in the mixing and fusion step, the mixing temperature is set at 220-250℃, the rotor speed is 40-60 r / min, and the mixing time is 8-15 min; in the integrated molding step, after controlling the temperature, the material is extruded through a special mold, and then calendered at 100-130℃ and cooled by water.

[0025] By adopting the above technical solution, the molding process is simplified by eliminating the mixing step. This effectively saves production costs and improves production efficiency while ensuring that the basic performance of the product meets requirements. Optionally, a manufacturing process for an environmentally friendly fiberglass flooring includes: S1. Pre-treatment of waste textiles: Waste textiles are directly fed into a crusher for crushing and granulation, without the need for sorting; S2. High-precision mixing: The pretreated material and the remaining raw materials are put into a mixing mixer and mixed at low speed for 10-20 minutes to obtain a uniform mixture. S3. Integrated molding: The mixed materials are fed into molding equipment for melting, plasticizing, and precision molding; S4. Post-processing: Surface modification, online inspection, grading and packaging of the molded flooring.

[0026] By adopting the above technical solution, the molding process is simplified by eliminating the mixing process. While ensuring that the basic performance of the product meets the requirements, production costs are effectively saved and production efficiency is improved. The resulting flooring can still maintain excellent waterproof and moisture-proof performance and can meet the needs of ordinary use scenarios.

[0027] In summary, this application includes at least one of the following beneficial technical effects: 1. Waterproof, mildew-proof, and highly weather-resistant: The product has a water absorption and expansion rate of ≤0.3%, is completely waterproof and moisture-proof, and is not prone to mildew or deformation. It can be used in humid and sun-exposed environments such as balconies and outdoors, and has a service life of more than 10 years, which is twice that of traditional wooden flooring. 2. Reduction, harmlessness, high value and recycling of waste textiles: Using waste textiles as the main raw material, accounting for 40-60%, blended and miscellaneous waste textiles can be used directly without fine sorting. It can realize the annual disposal of tens of thousands of tons of waste textiles, with a resource utilization rate of over 95%. It effectively solves the pollution problems of landfilling and incineration of waste textiles, and meets the national circular economy and "dual carbon" strategy and green and healthy building materials standards. 3. Completely solves the formaldehyde problem: The formula uses no adhesives and waste textile fibers and recycled plastics as core raw materials, and the formaldehyde emission of the product is far superior to that of wood flooring. 4. Significant cost advantages: Using waste textiles and recycled plastics as raw materials, the raw material cost is reduced by 35-55% compared to traditional wood-plastic flooring. The dedicated production line realizes automated continuous production, which increases production efficiency by 50% and the defect rate is ≤0.8%, making it highly competitive in the market. At the same time, the product is green, environmentally friendly, and recyclable. It can be 100% recycled and reused after being discarded, realizing "replacing wood with waste and plastic with textiles". Attached Figure Description

[0028] Figure 1 This is a flowchart illustrating the manufacturing process of the environmentally friendly fiber plastic flooring according to Embodiment 1 of this application; Figure 2 This is a structural diagram of the environmentally friendly fiber plastic flooring and its wood-grain-like surface structure in this application; Figure 3 This is a schematic diagram of the double-locking system of the environmentally friendly fiber plastic flooring in this application; Figure 4 This is a schematic diagram of the single-locking system of the environmentally friendly fiber plastic flooring in this application.

[0029] Reference numerals: 1. Floor; 11. Wood grain structure; 2. Double locking system; 21. Male buckle; 22. Female buckle; 3. Single locking system; 41. Groove. Detailed Implementation

[0030] The following is in conjunction with the appendix Figure 1 - Appendix Figure 3 This application will be described in further detail.

[0031] This application discloses an environmentally friendly fiber plastic flooring and its preparation process. Example 1

[0032] Reference Figure 1The environmentally friendly fiber plastic flooring disclosed in this embodiment contains the following raw materials by weight: 50 parts waste textile fiber particles, 25 parts recycled HDPE plastic, 8 parts talc powder activated by silane coupling agent, 3 parts environmentally friendly composite compatibilizer, 0.6 parts environmentally friendly lubricant, and 1.5 parts environmentally friendly color masterbatch.

[0033] Its preparation process is as follows: S1. Pre-treatment of waste textiles: Blended waste textiles are directly fed into a crusher for crushing and granulation to obtain waste textile fiber particles without the need for fine sorting. S2. High-precision mixing: The pretreated waste textile fiber particles, HDPE recycled plastic, and activated talc powder are put into a mixing mixer, and environmentally friendly composite compatibilizer, environmentally friendly lubricant, and environmentally friendly color masterbatch are added in sequence. The mixture is stirred at low speed for 15 minutes to obtain a uniform mixture. S3. Preparation and integrated molding of fiber-plastic composite materials: 1. Melting and plasticizing: The mixture is fed into a twin-screw extruder, and the temperature of each section is controlled: feeding section 210℃, melting section 230℃, conveying section 200℃, and die head section 190℃. Through the shearing and conveying action of the screw, the material is completely melted and plasticized to form a uniform melt, avoiding fiber carbonization and plastic decomposition caused by high temperature. 2. Internal mixing and fusion: The molten material is fed into an internal mixer, the mixing temperature is set to 230℃, the rotor speed is 50r / min, and the mixing time is 10min. Through the high-intensity shearing and kneading action of the internal mixer, the interfacial fusion between waste textile fibers and plastic substrate and inorganic reinforcing filler is further promoted, so that the fibers are more uniformly dispersed in the melt, while improving the plasticization quality and density of the mixture, laying a good foundation for subsequent molding. 3. Precision molding: After the melt is subjected to multi-stage temperature control, it is continuously extruded through a special precision mold adapted to the interlocking structure. After being shaped and calendered at 115℃, it is sent to a water cooling system to ensure the dimensional accuracy of the floor. S4. Post-processing: The formed flooring is sent to a wire drawing and polishing machine for surface modification to form an anti-slip layer and improve the anti-slip performance of the flooring; then, the dimensions, flatness, mechanical properties and environmental performance of the flooring are tested online by intelligent detection equipment to remove unqualified products and ensure that the finished product qualification rate is ≥99%; finally, qualified products are graded according to specifications, packaged with environmentally friendly packaging materials, and stored for later use, realizing a closed-loop production process.

[0034] The working principle of this application embodiment is as follows: This embodiment adopts a complete integrated molding process, and further improves the fusion effect of each component through a mixing process, ensuring the structural density and performance stability of the product. The resulting flooring has a water absorption rate of 0.025% and a formaldehyde emission level far below the E1 standard. All performance requirements are met, and it is suitable for humid environments such as kitchens, bathrooms, and outdoors. Example 2

[0035] The difference between this embodiment and Embodiment 1 is that the mixing and fusion process in the integrated molding stage is omitted, and the molten and plasticized material is directly fed into the precision molding process for extrusion. All other raw material components and process steps are the same as in Embodiment 1.

[0036] The working principle of Embodiment 2 of this application is as follows: This embodiment 2 simplifies the molding process by eliminating the mixing step. While ensuring that the basic performance of the product meets the requirements, it effectively saves production costs and improves production efficiency. The resulting flooring has a water absorption rate of 0.028%, which is still far superior to the performance indicators of traditional flooring and can meet the needs of ordinary use scenarios. Example 3

[0037] The environmentally friendly fiber plastic flooring 1 disclosed in this embodiment is described in reference to... Figure 2 The surface of flooring 1 has a wood grain structure 11, which is achieved using a one-time molding and simultaneous coloring and embossing technology. During the extrusion molding process of flooring 1, the molten flooring substrate is embossed using a special mold, while color masterbatch is injected into the embossed area. Under specific temperature and pressure conditions, the pigment in the color masterbatch is distributed in the concave and convex structure formed by embossing (different styles of embossing can be switched), thus completing the substrate shaping and texture construction simultaneously in one processing step, forming a realistic wood grain effect with natural color and three-dimensionality. At the same time, by changing the mold, single-sided or multi-sided coloring of flooring 1 can be achieved; the texture style can be diversified by changing the embossing roller, and the color and texture are integrated, overcoming the defects of traditional printed laminated flooring 1 such as stiff texture and easy wear and fading.

[0038] Reference Figure 3 and Figure 4 To improve installation efficiency and connection reliability, the two sides of the floor 1 are designed with a double locking system 2 and a single locking system 3.

[0039] Reference Figure 3The double-locking system 2 (left and right male and female grooves) consists of a male latch 21 on one side of the floorboard 1 and a female latch 22 on the other side. The male latch 21 has a raised tenon, while the female latch 22 has a precisely fitting female groove. During installation, the beveled surfaces of the tenon and female groove guide the horizontal locking of adjacent floorboards 1. This structure ensures a tight fit after the floorboards 1 are spliced, with smooth and concealed seams, supporting glue-free quick installation and disassembly, greatly improving construction convenience.

[0040] Reference Figure 4 The single-locking system 3 (left and right female grooves) consists of two parallel and independent grooves 41 set on the left and right edges of the floorboard 1, respectively. This structural design allows the floorboard 1 to form a double interlock with the male tenon on the edge of the adjacent floorboard 1 when it is spliced ​​laterally. Through the precise cooperation between the two female grooves and the corresponding male tenons, the lateral stability and connection strength of the floorboard 1 after splicing are significantly enhanced. This effectively prevents problems such as arching and gaps caused by thermal expansion and contraction or external forces during the use of the floorboard 1, and improves the overall installation quality and service life of the floorboard 1.

[0041] The working principle of Embodiment 3 of this application is as follows: This embodiment combines synchronous coloring and embossing technology with a double / single locking structure. While ensuring the core performance of the flooring in terms of environmental protection and waterproofing, it optimizes the decorative effect and installation performance. The texture is realistic and durable, and the locking is convenient and secure to install. It takes into account both aesthetics and practicality, and can meet the diverse decorative needs of high-end home decoration, commercial decoration and other applications.

[0042] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. An environmentally friendly fiberglass flooring, characterized in that: The raw materials of the environmentally friendly fiber plastic flooring (1) include, by weight: 40-60 parts of waste textile fiber particles, 20-30 parts of recycled plastic substrate, 5-10 parts of inorganic reinforcing filler, 2-5 parts of environmentally friendly composite compatibilizer, 0.3-1 parts of environmentally friendly lubricant, and 0.5-2.5 parts of environmentally friendly color masterbatch.

2. The environmentally friendly fiber-plastic flooring according to claim 1, characterized in that: The waste textile fiber particles are made by crushing waste textiles, which include cotton, polyester, nylon and blended waste textiles. Blended materials can be used directly without the need for fine sorting.

3. The environmentally friendly fiber-plastic flooring according to claim 1, characterized in that: The recycled plastic substrate is HDPE recycled plastic, which has undergone melt modification treatment to improve the interfacial bonding force with textile fibers.

4. The environmentally friendly fiber-plastic flooring according to claim 1, characterized in that: The inorganic reinforcing filler is talc, calcium carbonate, or calcium sulfate that has been activated by a silane coupling agent, with a particle size of 100-150 mesh.

5. The environmentally friendly fiber-plastic flooring according to claim 1, characterized in that: The floor (1) has a wood grain structure (11) on its surface. The wood grain structure (11) is prepared by one-time molding and simultaneous coloring and embossing technology. During the extrusion molding process, the molten substrate is embossed by a special mold, and a polymer co-extruded layer (containing color masterbatch) is simultaneously covered on the substrate surface, thus completing the shaping of the board and the construction of the texture.

6. The environmentally friendly fiber-plastic flooring according to claim 1, characterized in that: The floor (1) is provided with a single locking system (3) on both sides of the edge. The single locking system (3) consists of two parallel and independent grooves (41) on both sides of the floor (1).

7. The environmentally friendly fiber-plastic flooring according to claim 1, characterized in that: The floor (1) is provided with a double locking system (2) on both sides of the edge. The double locking system (2) is composed of a male buckle (21) on one side of the floor (1) and a female buckle (22) on the other side.

8. A manufacturing process for an environmentally friendly fiber-plastic flooring, used to produce the environmentally friendly fiber-plastic flooring as described in claim 1, characterized in that: include: S1. Pre-treatment of waste textiles: Waste textiles are directly fed into a crusher for crushing and granulation, without the need for sorting; S2. High-precision mixing: The pretreated material and the remaining raw materials are put into a mixing mixer and mixed at low speed for 10-20 minutes to obtain a uniform mixture. S3. Preparation and integrated molding of fiber-plastic composite materials: The mixture is fed into an internal mixing equipment for melting and plasticizing, internal mixing and fusion, and then precisely molded by an extrusion molding equipment; S4. Post-processing: The molded flooring (1) undergoes surface modification treatment, online testing, and graded packaging.

9. The preparation process of an environmentally friendly fiber-plastic flooring according to claim 8, characterized in that: In the preparation and integrated molding stage of the fiber-plastic composite material, a twin-screw extruder is used in the melt plasticizing step, and the temperature of each section of the twin-screw extruder is controlled as follows: feeding section 190-230℃, melting section 200-250℃, conveying section 190-220℃, and die head section 180-200℃; in the mixing and fusion step, the mixing temperature is set at 220-250℃, the rotor speed is 40-60 r / min, and the mixing time is 8-15 min. After temperature control during the integrated molding process, the material is extruded through a special mold, then calendered at 100-130℃ and cooled by water.

10. The preparation process of an environmentally friendly fiber-plastic flooring according to claim 8, characterized in that: Preparation and integrated molding of fiber-plastic composite materials: The materials are mixed in proportion and fed into the equipment for melting, plasticizing and precision molding.

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