Multi-layer co-extruded stone-plastic floor and manufacturing method thereof

Abstract

An embodiment of the present application discloses a multi-layer co-extruded stone plastic floor. The multi-layer co-extruded stone plastic floor includes: at least one co-extruded stone plastic layer, and the co-extruded stone plastic layer includes at least: a first stabilizing layer, a stone plastic rigid layer, and a second stabilizing layer from top to bottom; the first stabilizing layer and the second stabilizing layer have a dimensional change rate of 0-0.12% at -15°C - 80°C; at least one of the first stabilizing layer, the stone plastic rigid layer, and the second stabilizing layer contains ACR / nano-SiO2 composite particles. By adding stabilizing layers above and below the stone plastic rigid layer of the floor and adding ACR / nano-SiO2 composite particles to the floor material in this specification, the thermal stability of the floor material can be improved while ensuring the strength of the floor, and the thermal deformation of the floor material can be reduced.

Description

Technical Field

[0001] The present invention relates to the technical field of floor manufacturing, and in particular to a multi-layer co-extruded stone plastic floor and a manufacturing method thereof. Background Art

[0002] Stone plastic floor (SPC) is a multi-layer PVC floor with the advantages of mildew resistance, moisture resistance, fire resistance, wear resistance, simple installation and long service life. It is widely used for indoor floor decoration. Generally, the base material layer in the multi-layer stone plastic floor is extruded by a hot fusion process with natural stone powder (calcium carbonate powder) and polymer resin (polyvinyl chloride) as the main raw materials. In order to reduce costs, a large amount of inorganic fillers are usually added. However, PVC materials have poor thermal stability, and the addition of inorganic fillers will increase the brittleness of the material. In addition, because the floor is added with chlorinated polyvinyl chloride (CPE) additives, CPE toughening leads to a lower Vicat softening point of the floor, which is more prone to warping, arching, and lock buckle shedding and breaking, reducing the service life.

[0003] Therefore, it is necessary to provide a stone plastic floor with good thermal stability and not prone to thermal deformation. Summary of the invention

[0004] One of the embodiments of the present specification provides a multi-layer co-extruded stone-plastic floor, which includes at least one co-extruded stone-plastic layer, and the co-extruded stone-plastic layer includes at least: a first stable layer, a stone-plastic rigid layer and a second stable layer from top to bottom; the first stable layer and the second stable layer have a dimensional change rate of 0%-0.12% at -15°C-80°C; at least one of the first stable layer, the stone-plastic rigid layer and the second stable layer contains ACR / nano-SiO2 composite particles.

[0005] On the other hand, the present specification provides a method for manufacturing a multi-layer co-extruded stone plastic floor, the method comprising: mixing materials of at least one layer of a first stabilizing layer and a second stabilizing layer to obtain a first mixture, stirring the first mixture to obtain a first batch, wherein the first mixture comprises ACR / nano-SiO2 composite particles; mixing materials of a stone plastic rigid layer to obtain a second mixture, stirring the second mixture to obtain a second batch, wherein the second mixture comprises ACR / nano-SiO2 composite particles; extruding the first mixture and the second mixture through an extruder to extrude a co-extruded stone plastic layer, wherein the co-extruded stone plastic layer comprises a three-layer structure, namely, from top to bottom, the first stabilizing layer, the stone plastic rigid layer and the second stabilizing layer. BRIEF DESCRIPTION OF THE DRAWINGS

[0006] This specification will be further described in the form of exemplary embodiments, which will be described in detail by the accompanying drawings. These embodiments are not restrictive, and in these embodiments, the same number represents the same structure, wherein:

[0007] Figure 1 is a cross-sectional view of a co-extruded stone-plastic layer according to some embodiments of the present specification;

[0008] Figure 2 is a cross-sectional view of a multi-layer co-extruded stone-plastic floor according to some embodiments of this specification;

[0009] Figure 3 It is a flow chart of the manufacturing method of the multi-layer co-extruded stone plastic floor according to some embodiments of this specification. DETAILED DESCRIPTION

[0010] In order to more clearly illustrate the technical solutions of the embodiments of this specification, the following is a brief introduction to the drawings required for the description of the embodiments. Obviously, the drawings described below are only some examples or embodiments of this specification. For ordinary technicians in this field, this specification can also be applied to other similar scenarios based on these drawings without creative work. Unless it is obvious from the language environment or otherwise explained, the same reference numerals in the figures represent the same structure or operation.

[0011] As shown in this specification and claims, unless the context clearly indicates an exception, the words "a", "an", "an" and / or "the" do not refer to the singular and may also include the plural. Generally speaking, the terms "comprise" and "include" only indicate the inclusion of the steps and elements that have been clearly identified, and these steps and elements do not constitute an exclusive list. The method or device may also include other steps or elements.

[0012] Flowcharts are used in this specification to illustrate the operations performed by the system according to the embodiments of this specification. It should be understood that the preceding or following operations are not necessarily performed precisely in order. Instead, the steps may be processed in reverse order or simultaneously. At the same time, other operations may also be added to these processes, or one or more operations may be removed from these processes.

[0013] Figure 1 It is a cross-sectional view of a co-extruded stone-plastic layer according to some embodiments of the present specification.

[0014] The co-extruded stone plastic floor can be a floor with a multi-layer structure. In some embodiments, the co-extruded stone plastic floor can include at least one or more co-extruded stone plastic layers. The co-extruded stone plastic layer refers to a structure that provides support for the co-extruded stone plastic floor, for example, the co-extruded stone plastic layer can provide the main strength or hardness for the co-extruded stone plastic floor.

[0015] In some embodiments, the co-extruded stone plastic layer of the co-extruded stone plastic floor can be a multi-layer structure. The co-extruded stone plastic layer can include: a stabilizing layer and a stone plastic rigid layer. The stabilizing layer can refer to a structural layer that stabilizes other layers when other layers in the floor are deformed. The stone plastic rigid layer can be a structural layer that provides floor strength and support.

[0016] In some embodiments, the number of the stabilizing layer and / or the stone plastic rigid layer in the co-extruded stone plastic layer can be one or more layers, and the composition of each stabilizing layer or stone plastic rigid layer can be the same or different.

[0017] In some embodiments, the order of different layers in the co-extruded stone plastic layer can be that the stone plastic rigid layer is located between the stable layers, or that the stone plastic rigid layer is located above the stable layer. In some embodiments, two adjacent layers can be connected in a variety of ways. For example, they are connected by a binder, and the binder refers to a substance that makes objects bonded to each other. The binder can be PLA resin, phenolic resin, etc. For another example, they are connected by hot pressing. It is understandable that the connection method between different adjacent layers can be the same or different.

[0018] In some embodiments, the co-extruded plastic layer may include two stabilizing layers and a plastic rigid layer, such as Figure 1 The co-extruded stone-plastic layer 100 may include, from top to bottom, a first stabilizing layer 101 , a stone-plastic rigid layer 102 , and a second stabilizing layer 103 .

[0019] The first stabilizing layer may refer to a structural layer used to stabilize other layers in the co-extruded stone plastic floor. For example, the first stabilizing layer may be a structural layer that provides downward pulling force when other layers (e.g., UV coating, wear-resistant layer, etc.) above the first stabilizing layer in the co-extruded stone plastic floor (e.g., co-extruded stone plastic floor 200) expand and contract with heat or cold. For more details about other layers, see below.

[0020] In some embodiments, the first stabilizing layer can make the layer deform very little or not deform under the external force of other layers (e.g., other layers above the first stabilizing layer). For example, under the external force of 2000 psi (Pounds persquare inch), the deformation is less than 0.13mm. Wherein, 1psi=0.006895Mpa. For example, the first stabilizing layer can be a rigid material layer, that is, the material used can prevent the layer from deforming under the external force, thereby ensuring the compressive strength of the stone plastic floor and preventing brittle fracture.

[0021] In some embodiments, the first stabilization layer has a dimensional change rate of 0% to 0.12% at -15°C to 80°C.

[0022] In some embodiments, the composition of the first stabilization layer may include ACR / nano-SiO 2 composite particles.

[0023] ACR / nano-SiO2 composite particles are chemical substances generated by the composite of ACR (acrylate copolymer) and nano-SiO2. In some embodiments, the ACR / nano-SiO2 composite particles can be nano-particles. For example, the size of the composite particles ranges from 20 to 80 nm. It is understood that the size of the composite particles can be determined based on the nano-SiO2 that generates the composite particles.

[0024] In some embodiments, the ACR / nano-SiO2 composite particles can be produced by a variety of composite methods. For example, ACR and nano-SiO2 can be physically mixed or mechanically mixed to obtain ACR / nano-SiO2 composite particles. For another example, ACR and nano-SiO2 can be chemically mixed to obtain ACR / nano-SiO2 composite particles.

[0025] In some embodiments, nano-SiO2 particles surface-modified by a modifier are dispersed in an acrylate monomer, and allyl groups are introduced to polymerize with the monomer to obtain grafted polymer chains to form ACR / nano-SiO2 composite particles. For example, composite particles are prepared by mini-emulsion polymers of acrylic monomers modified with a methacrylic acid-3-trimethoxysilane (MPS) coupling agent.

[0026] In some embodiments, the second stabilizing layer may refer to a structural layer used to stabilize other layers in the co-extruded stone plastic floor. For example, the second stabilizing layer may be a structural layer that provides downward pulling force when other layers above the second stabilizing layer in the co-extruded stone plastic floor (e.g., the first stabilizing layer, the stone plastic rigid layer, the UV coating, the wear-resistant layer, etc.) expand or contract with heat or cold.

[0027] In some embodiments, the second stabilization layer can be configured to deform very little or not deform under the external force of other layers (e.g., other layers above the second stabilization layer). For example, under the external force of 2000 psi (Pounds per square inch), the deformation is less than 0.13 mm. Where 1 psi = 0.006895 MPa. Similar to the first stabilization layer, the second stabilization layer can be a rigid material layer.

[0028] In some embodiments, the second stabilization layer has a dimensional change rate of 0% to 0.12% at -15°C to 80°C.

[0029] In some embodiments, the second stabilization layer may include ACR / nano-SiO2 composite particles. For details about the ACR / nano-SiO2 composite particles, please refer to the above text and will not be described in detail.

[0030] The stone plastic rigid layer refers to the structural layer used to provide strength and support for the co-extruded stone plastic floor.

[0031] In some embodiments, the composition of the stone plastic rigid layer may include ACR / nano-SiO2 composite particles.

[0032] In some embodiments, the components of the stone-plastic rigid layer, the first stabilizing layer and the second stabilizing layer may further include other components, as will be described later.

[0033] Setting the co-extruded stone plastic layer on the floor as a three-layer structure can effectively control the overall stability of the multi-layer co-extruded stone plastic floor and effectively control the warping caused by the shrinkage of other layers of the multi-layer co-extruded stone plastic floor. At the same time, the setting of the stone plastic rigid layer in the co-extruded stone plastic layer ensures the strength of the multi-layer co-extruded stone plastic floor and improves the heat resistance and creep resistance of the multi-layer co-extruded stone plastic floor.

[0034] Moreover, by adding ACR / nano-SiO2 composite particles to the floor (for example, the stabilization layer or the stone plastic rigid layer), the performance of the floor can be significantly improved. ACR / nano-SiO2 composite particles are nanoparticles, which have size effects, local field effects, quantum effects, etc., which can make it show excellent properties that conventional materials do not have, including improving the strength of the floor, and improving the floor's resistance to thermal deformation by increasing the Vicat softening point of the floor.

[0035] As mentioned above, the co-extruded stone plastic floor may include other layers in addition to the co-extruded stone plastic layer. In some embodiments, the multi-layer co-extruded stone plastic floor may also include at least one of the following structural layers: UV coating, wear-resistant layer, color film layer. For more information about UV coating, wear-resistant layer, and color film layer, please refer to Figure 2 and its description.

[0036] In some embodiments, the ACR grafting rate on the surface of the ACR / nano-SiO 2 composite particles may be 70%-110%.

[0037] The ACR grafting rate refers to the efficiency of chemically bonding other functional groups on the molecular formula of the acrylic copolymer. Other functional groups refer to atoms or atomic groups that determine the chemical properties of organic compounds in addition to the compound itself. For example, other functional groups can be methyl, epoxy, etc.

[0038] Different grafting rates of ACR / nano-SiO2 composite particles will have different effects on the performance test results of multi-layer co-extruded stone plastic flooring. Specifically, the specific impact on the performance test results can be reflected through the following set of experiments.

[0039] In this group of experiments, the components of the first stabilizing layer and the second stabilizing layer in the multi-layer co-extruded stone plastic floor were set to include: 100 parts by weight of polyvinyl chloride, 270 parts by weight of inorganic filler, 1.5 parts by weight of polyethylene wax, 10 parts by weight of stabilizer, 1.4 parts by weight of stearic acid, 0.6 parts by weight of oxidized polyethylene wax, 15 parts by weight of ACR / nano-SiO2 composite particles with different grafting rates, and 0.5 parts by weight of carbon black; the components of the stone plastic rigid layer in the multi-layer co-extruded stone plastic floor were set to include: 100 parts by weight of polyvinyl chloride, 360 parts by weight of inorganic filler, 1.2 parts by weight of polyethylene wax, 5 parts by weight of stabilizer, 1.0 parts by weight of stearic acid, 10 parts by weight of ACR / nano-SiO2 composite particles with different grafting rates, and 10 parts by weight of glass beads.

[0040] The test results include the impact strength of the multi-layer co-extruded stone plastic floor. Impact strength is the energy absorbed per unit cross-sectional area when the sample breaks or fractures under the action of impact load. Impact load refers to the load acting on an object at a high speed in a very short time.

[0041] The test results are as follows:

[0042] (1) When the grafting rate of ACR / nano-SiO2 composite particles is 0%, the impact strength of the multi-layer co-extruded stone plastic floor is 1.8KJ / m 2 ;

[0043] (2) When the grafting rate of ACR / nano-SiO2 composite particles is 70%, the impact strength of the multi-layer co-extruded stone plastic floor is 10.5KJ / m 2 ;

[0044] (3) When the grafting rate of ACR / nano-SiO2 composite particles is 85%, the impact strength of the multi-layer co-extruded stone plastic floor is 10.8KJ / m 2 ;

[0045] (4) When the grafting rate of ACR / nano-SiO2 composite particles is 100%, the impact strength of the multi-layer co-extruded stone plastic floor is 11.3KJ / m 2 ;

[0046] (5) When the grafting rate of ACR / nano-SiO2 composite particles is 110%, the impact strength of the multi-layer co-extruded stone plastic floor is 10.8KJ / m 2 ;

[0047] The experimental data show that, under the same components, when the grafting rate of ACR / nano-SiO2 composite particles is 70%, 85%, 100% and 110%, the material has impact resistance, and the performance is significantly better than when the grafting rate of ACR / nano-SiO2 composite particles is 0%. The grafting rate of 0% can be understood as when the nano-SiO2 particles are mixed with ACR, ACR is not chemically bonded to SiO2, and ACR is not modified. The impact resistance can reflect the toughening effect of the material. The better the impact resistance, the better the toughening effect. It can be understood that the ACR / nano-SiO2 composite particles with a surface ACR grafting rate of 70%-110% have a good toughening effect. At the same time, the ACR / nano-SiO2 composite particles can be dispersed into fine particles suspended in polyvinyl chloride PVC, thereby increasing the toughening effect of polyvinyl chloride PVC, so that the toughening effect of polyvinyl chloride PVC with composite particles is significantly better than that of nano-SiO2 particles and unmodified ACR copolymers. These experimental data can serve as the basis for relevant embodiments.

[0048] In some embodiments, the ACR grafting rate on the surface of the ACR / nano-SiO2 composite particles can be 70%. The SPC floor has a better toughening effect by using the ACR / nano-SiO2 composite particles with a surface ACR grafting rate of 70%.

[0049] In some embodiments, the ACR grafting rate on the surface of the ACR / nano-SiO2 composite particles can be 85%. Using the ACR / nano-SiO2 composite particles with a surface ACR grafting rate of 85%, the stone plastic floor has a better toughening effect, and the impact resistance, impact strength, static bending strength, elongation displacement at break, and warpage of the stone plastic floor reach the best value of the comprehensive performance of the product design.

[0050] In some embodiments, the ACR grafting rate on the surface of the ACR / nano-SiO2 composite particles can be 100%. The SPC floor has the best toughening effect when the ACR / nano-SiO2 composite particles with a surface ACR grafting rate of 100% are used.

[0051] In some embodiments, the ACR grafting rate on the surface of the ACR / nano-SiO2 composite particles can be 110%. Using the ACR / nano-SiO2 composite particles with a surface ACR grafting rate of 110%, the stone plastic floor also has a good toughening effect.

[0052] As mentioned above, the stabilizing layer and the stone plastic rigid layer may be composed of multiple components, and in addition to the aforementioned ACR / nano-SiO2 composite particles, may also include polyvinyl chloride. In some embodiments, the stone plastic rigid layer may include polyvinyl chloride. At least one of the first stabilizing layer and the second stabilizing layer may include polyvinyl chloride.

[0053] In some embodiments, the mass content of polyvinyl chloride in the stone plastic rigid layer may be 18% to 21%. In some embodiments, the mass content of polyvinyl chloride in at least one of the first stable layer and the second stable layer may be 25% to 30%. In some embodiments, the amount of ACR / nano-SiO2 composite particles used is 10% to 15% of the mass content of polyvinyl chloride in the corresponding layer. For example, the ACR / nano-SiO2 composite particles in the stone plastic rigid layer are 10% to 15% of the mass content of polyvinyl chloride in the stone plastic rigid layer.

[0054] In some embodiments, the mass content of polyvinyl chloride in the stone plastic rigid layer can be 18%. The mass content of polyvinyl chloride in at least one of the first stable layer and the second stable layer can be 25%. In some embodiments, the amount of ACR / nano-SiO2 composite particles used can be 10% of the mass content of polyvinyl chloride in the corresponding layer.

[0055] In some embodiments, the mass content of polyvinyl chloride in the stone plastic rigid layer can be 19.5%. The mass content of polyvinyl chloride in at least one of the first stable layer and the second stable layer can be 27%. In some embodiments, the amount of ACR / nano-SiO2 composite particles used can be 12.5% ​​of the mass content of polyvinyl chloride in the corresponding layer.

[0056] In some embodiments, the mass content of polyvinyl chloride in the stone plastic rigid layer can be 20%. The mass content of polyvinyl chloride in at least one of the first stable layer and the second stable layer can be 28%. In some embodiments, the amount of ACR / nano-SiO2 composite particles used can be 13% of the mass content of polyvinyl chloride in the corresponding layer.

[0057] In some embodiments, the mass content of polyvinyl chloride in the stone plastic rigid layer can be 21%. The mass content of polyvinyl chloride in at least one of the first stable layer and the second stable layer can be 30%. In some embodiments, the amount of ACR / nano-SiO2 composite particles used can be 15% of the mass content of polyvinyl chloride in the corresponding layer.

[0058] In some embodiments, based on 526.8 parts by weight of the stone plastic rigid layer, the stone plastic rigid layer may include: 10-15 parts by weight of ACR / nano-SiO2 composite particles. For example, based on 526.8 parts by weight of the stone plastic rigid layer, the content of ACR / nano-SiO2 composite particles may be 12.5 parts by weight.

[0059] Different component contents of ACR / nano-SiO2 composite particles will have different effects on the performance test results of multi-layer co-extruded stone plastic flooring. Specifically, the specific impact on the performance test results can be reflected through the following set of experiments.

[0060] In this group of experiments, the components of the first stabilizing layer and the second stabilizing layer of the multi-layer co-extruded stone plastic floor were set to: 100 parts by weight of polyvinyl chloride, 270 parts by weight of inorganic filler, 1.5 parts by weight of polyethylene wax, 10 parts by weight of stabilizer, 1.4 parts by weight of stearic acid, 0.6 parts by weight of oxidized polyethylene wax, 15 parts by weight of ACR / nano-SiO2 composite particles, and 0.5 parts by weight of carbon black; the stone plastic rigid layer of the multi-layer co-extruded stone plastic floor was set to: 100 parts by weight of polyvinyl chloride, 360 parts by weight of inorganic filler, 1.2 parts by weight of polyethylene wax, 5 parts of stabilizer, 1.0 parts by weight of stearic acid, 10 parts by weight of glass beads, and the content of ACR / nano-SiO2 composite particles was used as a variable.

[0061] The test results include: impact strength, static bending strength, thermal deformation Vicat and heating warpage. Impact strength is the energy absorbed per unit cross-sectional area when the sample breaks or cracks under the impact load. Static bending strength is the pressure strength that the sample withstands when it is bent to the point of breaking. Thermal deformation Vicat is the amount of heat that the sample absorbs when it is bent by 1mm in a liquid heat transfer medium under a certain load and a certain constant temperature rise condition. 2 The temperature when the pressure needle is pressed into the depth of 1mm. Heating warpage refers to the degree of distortion of the surface of an object when the surface is heated at 80℃ for 6 hours and then returns to 23±2℃.

[0062] The test results are as follows:

[0063] (1) When the content of ACR / nano-SiO2 composite particles in the stone plastic rigid layer is 0%, the impact strength is 2.0KJ / m 2 ; Static bending strength is 20MPa; thermal deformation Vicat is 45℃; heating warpage is 1.5mm;

[0064] (2) When the content of ACR / nano-SiO2 composite particles in the stone plastic rigid layer is 10 parts, the impact strength is 13.0KJ / m 2 ; The static bending strength is 32MPa; the thermal deformation Vicat is 65℃; the heating warpage is 0.3mm;

[0065] (3) When the content of ACR / nano-SiO2 composite particles in the stone plastic rigid layer is 12.5 parts, the impact strength is 13.2KJ / m 2 ; The static bending strength is 32MPa; the thermal deformation Vicat is 65℃; the heating warpage is 0.28mm;

[0066] (4) When the content of ACR / nano-SiO2 composite particles in the stone plastic rigid layer is 15 parts, the impact strength is 13.5KJ / m 2 ; The static bending strength is 32MPa; the thermal deformation Vicat is 65℃; the heating warpage is 0.3mm;

[0067] (5) When the content of ACR / nano-SiO2 composite particles in the stone plastic rigid layer is 20 parts, the impact strength is 12.5KJ / m 2 ; The static bending strength is 30MPa; the thermal deformation Vicat is 65℃; the heating warpage is 0.70mm.

[0068] The experimental data show that when other components are the same, when the content of ACR / nano-SiO2 composite particles in the stone plastic rigid layer is 10 parts, 12.5 parts, and 15 parts, the impact resistance and thermal stability of the stone plastic floor are good, and the performance is significantly better than when the content of ACR / nano-SiO2 composite particles is 0 parts. It can be understood that when the stone plastic rigid layer adopts 10-15 parts by weight of ACR / nano-SiO2 composite particles, the stone plastic floor has good impact resistance and thermal stability. These experimental data can serve as the basis for relevant embodiments.

[0069] In some embodiments, the content of ACR / nano-SiO2 composite particles in the stone plastic rigid layer can be 10 parts by weight. When the plastic rigid layer contains 10 parts by weight of ACR / nano-SiO2 composite particles, the stone plastic floor has good impact resistance and thermal stability.

[0070] In some embodiments, the content of ACR / nano-SiO2 composite particles in the stone plastic rigid layer can be 12.5 parts by weight. When the plastic rigid layer contains 12.5 parts by weight of ACR / nano-SiO2 composite particles, the stone plastic floor has good impact resistance and thermal stability.

[0071] In some embodiments, the content of ACR / nano-SiO2 composite particles in the stone plastic rigid layer can be 13 parts by weight. When the plastic rigid layer contains 13 parts by weight of ACR / nano-SiO2 composite particles, the stone plastic floor has the best impact resistance and thermal stability.

[0072] In some embodiments, the content of ACR / nano-SiO2 composite particles in the stone plastic rigid layer can be 15 parts by weight. When the plastic rigid layer contains 15 parts by weight of ACR / nano-SiO2 composite particles, the stone plastic floor has good impact resistance and thermal stability.

[0073] In some embodiments, the stone plastic rigid layer may further include glass microspheres. Glass microspheres may be understood as hollow glass spheres of micro size. The density of the glass microspheres may be 0.50-0.70 g / cm 3 , the particle size can be between 45-55μm.

[0074] In some embodiments, the glass microspheres may be modified hollow glass microspheres. Modified hollow glass microspheres refer to hollow glass microspheres with changed properties. The changed properties may include: changes in the lipophilic properties of the surface, different states (e.g., dispersibility or fluidity in a molten state, etc.). In some embodiments, the glass microsphere content may be 10%-15% of the mass content of polyvinyl chloride in the stone plastic rigid layer. For example, the glass microsphere content may be 10% of the mass content of polyvinyl chloride in the stone plastic rigid layer. For another example, the glass microsphere content may be 12.5% ​​of the mass content of polyvinyl chloride in the stone plastic rigid layer. For another example, the glass microsphere content may be 14% of the mass content of polyvinyl chloride in the stone plastic rigid layer. For another example, the glass microsphere content may be 15% of the mass content of polyvinyl chloride in the stone plastic rigid layer.

[0075] Adding glass beads to the polyvinyl chloride component of the stone plastic rigid layer can improve the material processing fluidity, and at the same time can effectively improve the strength, creep resistance and heat resistance stability of the floor's rigid stone plastic layer, making the floor less likely to deform during use.

[0076] In some embodiments, the composition of the stone plastic rigid layer includes 10-15 parts by weight of glass microspheres based on 526.8 parts by weight of the stone plastic rigid layer. For example, based on 526.8 parts by weight of the stone plastic rigid layer, the glass microsphere content can be 12.5 parts by weight.

[0077] Different content of glass beads will have different effects on the performance test results of multi-layer co-extruded stone plastic floor. Specifically, the specific impact on the performance test results can be reflected through the following set of experiments.

[0078] In this group of experiments, the first stabilizing layer and the second stabilizing layer of the multi-layer co-extruded stone plastic floor were set to: 100 parts by weight of polyvinyl chloride, 270 parts by weight of inorganic filler, 1.5 parts by weight of polyethylene wax, 10 parts by weight of stabilizer, 1.4 parts by weight of stearic acid, 0.6 parts by weight of oxidized polyethylene wax, 15 parts by weight of ACR / nano-SiO2 composite particles, and 0.5 parts by weight of carbon black; the stone plastic rigid layer of the multi-layer co-extruded stone plastic floor was set to: 100 parts by weight of polyvinyl chloride, 360 parts by weight of inorganic filler, 1.2 parts by weight of polyethylene wax, 5 parts by weight of stabilizer, 1.0 parts by weight of stearic acid, 10 parts by weight of ACR / nano-SiO2 composite particles, and the glass microbead content was used as a variable.

[0079] The test results include: static bending strength, elongation displacement at break, heating warpage, heating dimensional change rate, and thermal deformation Vicat. Among them, the elongation displacement at break refers to the displacement of the object when it is crushed. The heating dimensional change rate refers to the degree of change in the size of the object when it is heated at 80℃ for 6 hours and then returns to 23±2℃.

[0080] The test results are as follows:

[0081] (1) When the content of glass microbeads in the rigid layer of stone plastic is 0 parts, the static bending strength is 20MPa; the elongation displacement at break is 14mm; the heating warpage is 1.2mm; the heating dimensional change rate is 0.190%; the thermal deformation Vicat is 45℃;

[0082] (2) When the content of glass microbeads in the rigid layer of stone plastic is 10 parts, the static bending strength is 32MPa; the elongation displacement at break is 12mm; the heating warpage is 0.25mm; the heating dimensional change rate is 0.050%; and the thermal deformation Vicat is 65℃;

[0083] (3) When the content of glass microbeads in the rigid layer of stone plastic is 12.5 parts, the static bending strength is 32.5MPa; the elongation displacement at break is 11mm; the heating warpage is 0.35mm; the heating dimensional change rate is 0.060%; and the thermal deformation Vicat is 65℃;

[0084] (4) When the content of glass microbeads in the rigid layer of stone plastic is 15 parts, the static bending strength is 34MPa; the elongation displacement at break is 10mm; the heating warpage is 0.35mm; the heating dimensional change rate is 0.055%; the thermal deformation Vicat is 65℃;

[0085] (5) When the content of glass microbeads in the rigid layer of stone plastic is 20 parts, the static bending strength is 36MPa; the elongation displacement at break is 4mm; the heating warpage is 0.80mm; the heating dimensional change rate is 0.220%; and the thermal deformation Vicat is 55℃.

[0086] The experimental data show that when other components are the same, when the content of glass microbeads in the rigid layer of the stone plastic is 10 parts, 12.5 parts, and 15 parts, the impact resistance and thermal stability of the stone plastic floor are good, and the performance is significantly better than when the content of glass microbeads is 0 parts. It can be understood that when the composition of the rigid layer of the stone plastic adopts glass microbeads with a content of 10-15 parts by weight, the impact resistance and thermal stability of the stone plastic floor are good. These experimental data can be used as the basis for relevant embodiments.

[0087] In some embodiments, the content of glass microbeads in the stone plastic rigid layer can be 10 parts by weight. When the stone plastic rigid layer contains 10 parts by weight of glass microbeads, the stone plastic floor has good impact resistance and thermal stability.

[0088] In some embodiments, the content of glass microbeads in the stone plastic rigid layer can be 12.5 parts by weight. When the stone plastic rigid layer contains 12.5 parts by weight of glass microbeads, the stone plastic floor has good impact resistance and thermal stability.

[0089] In some embodiments, the content of glass microbeads in the stone plastic rigid layer can be 14 parts by weight. When the stone plastic rigid layer contains 14 parts by weight of glass microbeads, the stone plastic floor has good impact resistance and thermal stability.

[0090] In some embodiments, the content of glass microbeads in the stone plastic rigid layer can be 15 parts by weight. When the stone plastic rigid layer contains 15 parts by weight of glass microbeads, the stone plastic floor has good impact resistance and thermal stability.

[0091] In some embodiments, the stabilization layer and the stone plastic rigid layer may further include other components. For example, the components of the stone plastic rigid layer may include inorganic fillers, polyethylene wax, stabilizers, stearic acid or other additives, such as colorants, plasticizers, etc., in addition to polyvinyl chloride. For another example, the stabilization layer (the first stabilization layer and / or the second stabilization layer) may include inorganic fillers, polyethylene wax, stabilizers, stearic acid, oxidized polyethylene wax, carbon black or other additives, in addition to polyvinyl chloride.

[0092] In some embodiments, the proportions of other components of the stabilizing layer and the stone plastic rigid layer can be selected according to different situations. For example, based on 353.5 parts by weight of the first stabilizing layer and / or the second stabilizing layer, the composition of the stabilizing layer may include 100 parts by weight of polyvinyl chloride, 12.5 parts by weight of ACR / nano-SiO2 composite particles, and at least one of the following components: 240 parts by weight of inorganic filler, 1.2 parts by weight of polyethylene wax, 8 parts by weight of stabilizer, 1.1 parts by weight of stearic acid, 0.4 parts by weight of oxidized polyethylene wax, and 0.3 parts by weight of carbon black. For another example, based on 526.8 parts by weight of the stone plastic rigid layer, the composition of the stone plastic rigid layer also includes 100 parts by weight of polyvinyl chloride and at least one of the following components: 392.5 parts by weight of inorganic filler, 1.5 parts by weight of polyethylene wax, 6.5 parts by weight of stabilizer, and 1.3 parts by weight of stearic acid.

[0093] The stabilizer is a reagent that keeps the structure of the polymer compound stable. For example, the stabilizer can be calcium stearate, dibasic lead salt, etc.

[0094] Inorganic fillers can be understood as added inorganic fillers. Inorganic fillers can include silicate inorganic fillers, carbonate inorganic fillers and sulfate inorganic fillers. For example, silicate inorganic fillers can be clay, mica powder, talcum powder, feldspar powder, etc. Carbonate inorganic fillers can be heavy calcium carbonate, light calcium carbonate and ultrafine calcium carbonate, etc. Sulfate inorganic fillers can be barium sulfate and lithopone, etc.

[0095] Different contents of the first stabilizing layer components will have different effects on the performance test results of the multi-layer co-extruded stone plastic floor. Specifically, the specific impact on the performance test results can be reflected through the following set of experiments.

[0096] In the following test, the thickness of the wear-resistant layer is 0.3mm, the thickness of the co-extruded stone plastic layer is 3.7mm, of which the first stabilizing layer is 0.95mm, the rigid layer is 1.8mm, and the second stabilizing layer is 0.95mm. The components of the rigid layer of the multi-layer co-extruded stone plastic floor are: 100 parts by weight of polyvinyl chloride, 360 parts by weight of inorganic filler, 1.2 parts by weight of polyethylene wax, 5 parts by weight of stabilizer, 1.0 parts by weight of stearic acid, 10 parts by weight of ACR / nano-SiO2 composite particles, and 10 parts by weight of glass microspheres. The components of the first stabilizing layer are set to be different.

[0097] The test results include: room temperature warpage, heating warpage, heating dimensional change rate, and low temperature dimensional change rate. Among them, room temperature warpage refers to the degree of distortion of the surface of an object at 25°C. Low temperature dimensional change rate refers to the degree of dimensional change of an object when it is restored to 23±2°C after being kept at -18°C for 6 hours.

[0098] The test results are as follows:

[0099] (1) When the stabilizing layer composition is: 100 parts by weight of polyvinyl chloride, 270 parts by weight of inorganic filler, 1.5 parts by weight of polyethylene wax, 10 parts by weight of stabilizer, 1.4 parts by weight of stearic acid, 0.6 parts by weight of oxidized polyethylene wax, 15 parts by weight of ACR / nano-SiO2 composite particles, and 0.5 parts by weight of carbon black, the warpage at room temperature is 0.20 mm, the heating warpage is 0.25 mm, the heating dimensional change rate is 0.05%, and the low temperature dimensional change rate is 0.06%;

[0100] (2) When the stabilizing layer components are: 100 parts by weight of polyvinyl chloride, 240 parts by weight of inorganic filler, 1.2 parts by weight of polyethylene wax, 7.5 parts by weight of stabilizer, 1.1 parts by weight of stearic acid, 0.4 parts by weight of oxidized polyethylene wax, 12.5 parts by weight of ACR / nano-SiO2 composite particles, and 12.5 parts by weight of carbon black, the warpage at room temperature is 0.30 mm, the heating warpage is 0.50 mm, the heating dimensional change rate is 0.08%, and the low temperature dimensional change rate is 0.09%;

[0101] (3) When the stabilizing layer composition is: 100 parts by weight of polyvinyl chloride, 210 parts by weight of inorganic filler, 0.9 parts by weight of polyethylene wax, 6 parts by weight of stabilizer, 0.8 parts by weight of stearic acid, 0.2 parts by weight of oxidized polyethylene wax, 10 parts by weight of ACR / nano-SiO2 composite particles, and 0.5 parts by weight of carbon black, the warpage at room temperature is 0.35 mm, the heating warpage is 0.60 mm, the heating dimensional change rate is 0.075%, and the low temperature dimensional change rate is 0.10%;

[0102] (4) When the stabilizing layer composition is: 100 parts by weight of polyvinyl chloride, 180 parts by weight of inorganic filler, 0.9 parts by weight of polyethylene wax, 6 parts by weight of stabilizer, 0.8 parts by weight of stearic acid, 0.2 parts by weight of oxidized polyethylene wax, 10 parts by weight of ACR / nano-SiO2 composite particles, and 0.5 parts by weight of carbon black, the warpage at room temperature is 0.75 mm, the heating warpage is 0.90 mm, the heating dimensional change rate is 0.18%, and the low temperature dimensional change rate is 0.20%;

[0103] (5) When the components of the stabilizing layer are: 100 parts by weight of polyvinyl chloride, 300 parts by weight of inorganic filler, 1.5 parts by weight of polyethylene wax, 10 parts by weight of stabilizer, 1.4 parts by weight of stearic acid, 0.6 parts by weight of oxidized polyethylene wax, 15 parts by weight of ACR / nano-SiO2 composite particles, and 0.5 parts by weight of carbon black, the warpage at room temperature is 0.65 mm, the heating warpage is 1.50 mm, the heating dimensional change rate is 0.13%, and the low temperature dimensional change rate is 0.15%.

[0104] Experimental data show that when the thickness of each layer and the components of the stone-plastic rigid layer are the same, the floor has good anti-deformation ability and thermal stability when it contains 100 parts by weight of polyvinyl chloride, 270 parts by weight of inorganic filler, 1.5 parts by weight of polyethylene wax, 10 parts by weight of stabilizer, 1.4 parts by weight of stearic acid, 0.6 parts by weight of oxidized polyethylene wax, 15 parts by weight of ACR / nano-SiO2 composite particles, and 0.5 parts by weight of carbon black.

[0105] It can be understood that based on 363.5 parts by weight of the first stabilizing layer, the first stabilizing layer comprises the following components: 100 parts by weight of polyvinyl chloride, 210-270 parts by weight of inorganic filler, 0.9-1.5 parts by weight of polyethylene wax, 6-10 parts by weight of stabilizer, 0.8-1.4 parts by weight of stearic acid, 0.2-0.6 parts by weight of oxidized polyethylene wax, 10-15 parts by weight of ACR / nano-SiO2 composite particles, 0.1-0.5 parts by weight of carbon black, the floor has good anti-deformation ability and thermal stability. These experimental data can be used as the basis of relevant embodiments.

[0106] In some embodiments, based on 363.5 parts by weight of the first stabilizing layer, the first stabilizing layer comprises the following components: 100 parts by weight of polyvinyl chloride, 210-270 parts by weight of inorganic filler, 0.9-1.5 parts by weight of polyethylene wax, 6-10 parts by weight of stabilizer, 0.8-1.4 parts by weight of stearic acid, 0.2-0.6 parts by weight of oxidized polyethylene wax, 10-15 parts by weight of ACR / nano-SiO2 composite particles, and 0.1-0.5 parts by weight of carbon black.

[0107] In some embodiments, based on 363.5 parts by weight of the first stabilizing layer, the first stabilizing layer may include the following components: 100 parts by weight of polyvinyl chloride, 210 parts by weight of inorganic filler, 0.9 parts by weight of polyethylene wax, 6 parts by weight of stabilizer, 0.8 parts by weight of stearic acid, 0.2 parts by weight of oxidized polyethylene wax, 10 parts by weight of ACR / nano-SiO2 composite particles, and 0.1 parts by weight of carbon black. With the configuration of the composition ratio in the first stabilizing layer, the floor has better anti-deformation ability and thermal stability.

[0108] In some embodiments, based on 363.5 parts by weight of the first stabilizing layer, the first stabilizing layer may include the following components: 100 parts by weight of polyvinyl chloride, 240 parts by weight of inorganic filler, 1.2 parts by weight of polyethylene wax, 8 parts by weight of stabilizer, 1.1 parts by weight of stearic acid, 0.4 parts by weight of oxidized polyethylene wax, 12.5 parts by weight of ACR / nano-SiO2 composite particles, and 0.3 parts by weight of carbon black. With the configuration of the composition ratio in the first stabilizing layer, the floor has better anti-deformation ability and thermal stability.

[0109] In some embodiments, based on 363.5 parts by weight of the first stabilizing layer, the first stabilizing layer may include the following components: 100 parts by weight of polyvinyl chloride, 270 parts by weight of inorganic filler, 1.5 parts by weight of polyethylene wax, 10 parts by weight of stabilizer, 1.4 parts by weight of stearic acid, 0.6 parts by weight of oxidized polyethylene wax, 15 parts by weight of ACR / nano-SiO2 composite particles, and 0.5 parts by weight of carbon black. With the configuration of the composition ratio in the first stabilizing layer, the floor has better anti-deformation ability and thermal stability.

[0110] In some embodiments, the thickness range of the first stabilizing layer may be between 0.55 mm and 1.15 mm, the thickness range of the stone-plastic rigid layer may be between 1.8 mm and 2.2 mm, and the thickness range of the first stabilizing layer may be between 0.55 mm and 1.15 mm.

[0111] In some embodiments, the thickness ratio of the stabilizing layer (the first stabilizing layer or the second stabilizing layer) to the stone plastic rigid layer may be 1:1.8-2.2. In some embodiments, the thickness of the first stabilizing layer, the second stabilizing layer, and the stone plastic rigid layer may be the same or different. For example, the thickness ratio of the first stabilizing layer, the stone plastic rigid layer, and the second stabilizing layer may be 1:1.8-2.2:1.

[0112] Different thickness of the first stabilizing layer will have different effects on the performance test results of the multi-layer co-extruded stone plastic floor. Specifically, the specific impact on the performance test results can be reflected through the following set of experiments.

[0113] In this group of experiments, the first stabilizing layer and the second stabilizing layer were set to: 100 parts by weight of polyvinyl chloride, 270 parts by weight of inorganic filler, 1.5 parts by weight of polyethylene wax, 10 parts by weight of stabilizer, 1.4 parts by weight of stearic acid, 0.6 parts by weight of oxidized polyethylene wax, 15 parts by weight of ACR / nano-SiO2 composite particles, and 0.5 parts by weight of carbon black; the stone plastic rigid layer was set to: 100 parts by weight of polyvinyl chloride, 360 parts by weight of inorganic filler, 1.2 parts by weight of polyethylene wax, 5 parts by weight of stabilizer, 1.0 parts by weight of stearic acid, 10 parts by weight of ACR / nano-SiO2 composite particles, and 10 parts by weight of glass microspheres. In different experimental cases, different thicknesses of the first stabilizing layer were used to test the performance of the floor in terms of normal temperature warpage, heating warpage, heating dimensional change rate, and low temperature dimensional change rate.

[0114] The test results are as follows:

[0115] (1) The thickness of the wear-resistant layer is 0.3 mm, the thickness of the co-extruded stone-plastic layer is 3.7 mm, the thickness of the first stable layer is 0.95 mm, the thickness of the rigid layer is 1.8 mm, and the thickness of the second stable layer is 0.95 mm. The test results are: the warpage at room temperature is 0.20 mm; the heating warpage is 0.25 mm; the heating dimensional change rate at 80 ° C is 0.05%; the low temperature dimensional change rate at -18 ° C is 0.06%;

[0116] (2) The thickness of the wear-resistant layer is 0.3 mm, the thickness of the co-extruded substrate is 3.7 mm, the thickness of the first stable layer is 0.75 mm, the thickness of the rigid layer is 2.0 mm, and the thickness of the second stable layer is 0.95 mm. The test results are: the warpage at room temperature is 0.70 mm; the heating warpage is 0.70 mm; the heating dimensional change rate at 80 ° C is 0.12%; the low temperature dimensional change rate at -18 ° C is 0.20%;

[0117] (3) The thickness of the wear-resistant layer is 0.3 mm, the thickness of the co-extruded stone-plastic layer is 3.7 mm, of which the thickness of the first stable layer is 0.55 mm, the thickness of the rigid layer is 2.2 mm, and the thickness of the second stable layer is 0.95 mm. The test results are: the warpage at room temperature is 0.85 mm; the heating warpage is 0.70 mm; the heating dimensional change rate at 80 ° C is 0.25%; the low temperature dimensional change rate at -18 ° C is 0.22%;

[0118] (4) The thickness of the wear-resistant layer is 0.3 mm, the thickness of the co-extruded stone-plastic layer is 3.7 mm, of which the thickness of the first stable layer is 1.15 mm, the thickness of the rigid layer is 1.8 mm, and the thickness of the second stable layer is 0.75 mm. The test results are: the warpage at room temperature is 1.0 mm; the heating warpage is 1.2 mm; the heating dimensional change rate at 80°C is 0.30%; the low temperature dimensional change rate at -18°C is 0.18%.

[0119] Experimental data show that when the components of the stabilizing layer and the rigid layer are as described above and the thickness of the second stabilizing layer is constant, when the thickness of the first stabilizing layer is 0.95 mm, the SPC floor has good heat resistance and stability, which is significantly better than the cases with thicknesses of 0.75 mm, 0.55 mm, and 1.15 mm. These data can serve as the basis for relevant embodiments.

[0120] In some embodiments, the thickness ratio of the first stabilizing layer to the stone plastic rigid layer may be 1:1.8. By setting this thickness, the stone plastic floor has good heat resistance and stability.

[0121] In some embodiments, the thickness ratio of the first stabilizing layer to the stone plastic rigid layer can be 1:1.9. By setting this thickness, the stone plastic floor has good heat resistance and stability.

[0122] In some embodiments, the thickness ratio of the first stabilizing layer to the stone-plastic rigid layer can be 1:2.0. By setting this thickness ratio, the plastic floor has good heat resistance and stability.

[0123] In some embodiments, the thickness ratio of the first stabilizing layer to the stone plastic rigid layer can be 1:2.2. By setting this thickness, the stone plastic floor has good heat resistance and stability.

[0124] Different thickness of the second stabilizing layer will have different effects on the performance test results of the multi-layer co-extruded stone plastic floor. Specifically, the specific impact on the performance test results can be reflected through the following set of experiments.

[0125] In this group of experiments, the first stabilization layer and the second stabilization layer were set to: 100 parts by weight of polyvinyl chloride, 270 parts by weight of inorganic filler, 1.5 parts by weight of polyethylene wax, 10 parts by weight of stabilizer, 1.4 parts by weight of stearic acid, 0.6 parts by weight of oxidized polyethylene wax, 15 parts by weight of ACR / nano-SiO2 composite particles, and 0.5 parts by weight of carbon black; the stone plastic rigid layer was set to: 100 parts by weight of polyvinyl chloride, 360 parts by weight of inorganic filler, 1.2 parts by weight of polyethylene wax, 5 parts by weight of stabilizer, 1.0 parts by weight of stearic acid, 10 parts by weight of ACR / nano-SiO2 composite particles, and 10 parts by weight of glass beads. In different experimental cases, the second stabilization layer of different thicknesses was used to test the performance of the floor in terms of normal temperature warpage, heating warpage, heating dimensional change rate, and low temperature dimensional change rate.

[0126] The test results are as follows:

[0127] (1) The thickness of the wear-resistant layer is 0.3 mm, the thickness of the co-extruded stone-plastic layer is 3.7 mm, of which the first stable layer is 0.95 mm, the rigid layer is 1.8 mm, and the second stable layer is 0.95 mm. The test results are: the warpage at room temperature is 0.20 mm; the heating warpage is 0.25 mm; the heating dimensional change rate at 80 ° C is 0.05%; the low temperature dimensional change rate at -18 ° C is 0.06%;

[0128] (2) The thickness of the wear-resistant layer is 0.3 mm, the thickness of the co-extruded stone-plastic layer is 3.7 mm, of which the first stable layer is 0.95 mm, the rigid layer is 2.0 mm, and the second stable layer is 0.75 mm. The test results are: the warpage at room temperature is 1.20 mm; the heating warpage is 1.0 mm; the heating dimensional change rate at 80 ° C is 0.18%; the low temperature dimensional change rate at -18 ° C is 0.23%;

[0129] (3) The thickness of the wear-resistant layer is 0.3 mm, the thickness of the co-extruded stone-plastic layer is 3.7 mm, of which the first stable layer is 0.95 mm, the rigid layer is 2.2 mm, and the second stable layer is 0.55 mm. The test results are: the warpage at room temperature is 2.0 mm; the heated warpage is 2.5 mm; the heating dimensional change rate at 80 ° C is 0.25%; the low temperature dimensional change rate at -18 ° C is 0.35%;

[0130] (4) The thickness of the wear-resistant layer is 0.3 mm, the thickness of the co-extruded stone-plastic layer is 3.7 mm, of which the first stable layer is 0.75 mm, the rigid layer is 1.8 mm, and the second stable layer is 1.15 mm. The test results are: the warpage at room temperature is 0.80 mm; the heated warpage is 0.70 mm; the heating dimensional change rate at 80°C is 0.20%; the low temperature dimensional change rate at -18°C is 0.25%.

[0131] Experimental data show that when the components of the stabilizing layer and the rigid layer are as described above, and the thickness of the first stabilizing layer is constant, when the thickness of the second stabilizing layer is 0.95 mm, the SPC floor has good heat resistance and stability, which is significantly better than the cases with thicknesses of 0.75 mm, 0.55 mm, and 1.15 mm. These data can serve as the basis for relevant embodiments.

[0132] In some embodiments, the thickness ratio of the second stabilizing layer to the stone plastic rigid layer can be 1:1.8. By setting this thickness, the stone plastic floor has good heat resistance and stability.

[0133] In some embodiments, the thickness ratio of the second stabilizing layer to the stone plastic rigid layer can be 1:1.9. By setting this thickness, the stone plastic floor has good heat resistance and stability.

[0134] In some embodiments, the thickness ratio of the second stabilizing layer to the stone plastic rigid layer can be 1:2.0. By setting this thickness, the stone plastic floor has good heat resistance and stability.

[0135] In some embodiments, the thickness ratio of the second stabilizing layer to the stone plastic rigid layer can be 1:2.2. By setting this thickness, the stone plastic floor has good heat resistance and stability.

[0136] In summary, only when the thickness ratio of the first stable layer, the stone plastic rigid layer and the second stable layer is 1:1.8~2.2:1, can the first stable layer and the second stable layer meet the dimensional change rate of 0%~0.12% at -15℃~80℃, so that the stone plastic floor has good heat resistance and stability. If the thickness ratio of the first stable layer, the stone plastic rigid layer and the second stable layer does not meet the 1:1.8~2.2:1, the dimensional change rate of the first stable layer and the second stable layer at -15℃~80℃ will be greater than 0%~0.12%, and the heat resistance and stability of the stone plastic floor will be poor.

[0137] Figure 2 It is a cross-sectional view of a multi-layer co-extruded stone-plastic floor according to some embodiments of this specification.

[0138] In some embodiments, the multi-layer co-extruded stone-plastic floor comprises a co-extruded stone-plastic layer 100 , a UV coating 210 , a wear-resistant layer 220 , and a color film layer 230 .

[0139] The UV coating 210 can be a polyurethane ultraviolet curing coating layer coated on the surface. In some embodiments, the UV coating has the effects of wear resistance, anti-fouling, waterproof and moisture-proof.

[0140] The wear-resistant layer 220 may be a structural layer for alleviating mechanical wear.

[0141] In some embodiments, the thickness of the wear-resistant layer affects the thickness of the first stable layer and the second stable layer. Specifically, when the thickness of the wear-resistant layer is larger, the strength required to be provided by the rigid structural layer is greater, and the thickness of the first stable layer and the second stable layer is larger. For example, when the total thickness of the multi-layer co-extruded stone plastic floor is constant, when the thickness of the wear-resistant layer is 0.3mm, the thickness ratio of the first stable layer, the stone plastic rigid layer, and the second stable layer can be 1:2.2:1; when the thickness of the wear-resistant layer is 0.40mm, the thickness ratio of the first stable layer, the stone plastic rigid layer, and the second stable layer can be 1:2.0:1.

[0142] The color film layer 230 may be a decorative layer structure layer in the floor structure, and may provide effects such as color and pattern.

[0143] In some embodiments, two adjacent layers of the UV coating, the wear-resistant layer, and the color film layer can be connected in a variety of ways. For example, they can be connected by an adhesive. Another example is that they can be connected by hot pressing. It is understandable that the connection methods between different adjacent layers can be the same or different.

[0144] Figure 3 It is a flow chart of a manufacturing method for preparing a multi-layer co-extruded stone plastic floor according to some embodiments of this specification.

[0145] Step 301 : mixing materials in at least one of the first stable layer and the second stable layer to obtain a first mixed material, and stirring the first mixed material to obtain a first batch.

[0146] For the definitions of the first stable layer and the second stable layer, please refer to Figure 1 The material of the first stabilization layer refers to the raw materials required for manufacturing the first stabilization layer. The material of the second stabilization layer refers to the raw materials required for manufacturing the second stabilization layer. The first mixed material refers to the material obtained by mixing the components in the first stabilization layer or the second stabilization layer in the description of step 303. The first batching refers to the material obtained after the first mixed material is processed. The processing process may include one or more of stirring and heating operations, cooling operations, etc.

[0147] In some embodiments, the first mixed material may include ACR / nano-SiO2 composite particles. For the definition of ACR / nano-SiO2 composite particles, see Figure 1 Description.

[0148] In some embodiments, the materials of at least one layer of the first stabilization layer and the second stabilization layer can be fed into a high-speed mixer through an automatic metering system, stirred and heated to 110-125°C, and then fed into a low-speed mixer to be cooled to 45-60°C and then put into a discharge tank to obtain the first ingredient.

[0149] The automatic metering system can be a digital system for quantitative proportioning of various materials.

[0150] The high-speed mixer may be a mixer with a rotation speed in the range of 860 r / min-1500 r / min, which heats up by self-friction or has a built-in heating device.

[0151] The low-speed mixer may be a mixer with a rotation speed in the range of 325 r / min-650 r / min and a built-in heat dissipation device. The discharge tank may be a tank for collecting the material after mixing.

[0152] Step 302, mixing the materials of the stone plastic rigid layer to obtain a second mixed material, and stirring the second mixed material to obtain a second batch.

[0153] The material of the stone plastic rigid layer refers to the raw material required for manufacturing the stone plastic rigid layer. The second mixed material refers to the material obtained by mixing the components in the stone plastic rigid layer according to the proportion in the description of step 303. The second batch refers to the material obtained after the second mixed material is processed. The processing process may include one or more of stirring and heating operations, cooling operations, etc.

[0154] In some embodiments, the second mixed material may include ACR / nano-SiO2 composite particles. For the definition of ACR / nano-SiO2 composite particles, see Figure 1 Description.

[0155] In some embodiments, the material of the stone plastic rigid layer can be fed into a high-speed mixer through an automatic metering system, stirred and heated to 110-125°C, then fed into a low-speed mixer and cooled to 45-60°C, and then put into a discharge tank to obtain the second ingredient.

[0156] In some embodiments, the material of the stone plastic rigid layer can be fed into a high-speed mixer through an automatic metering system, stirred and heated to 115° C., then fed into a low-speed mixer and cooled to 55° C. before being put into a discharge tank to obtain a second ingredient.

[0157] For the definitions of the automatic metering system, the high-speed mixer, the low-speed mixer, and the discharge tank, please refer to the description of step 301.

[0158] Step 303: extrude the first mixed material and the second mixed material through an extruder to form a co-extruded stone-plastic layer.

[0159] For the definition of co-extruded stone-plastic layer, please refer to Figure 1 Explanation. An extruder refers to a device that passes a plastic raw material in a viscous flow state after heating through an extrusion die to form a mold body with a cross-section similar to the shape of a mold. The viscous flow state refers to the mechanical state of an amorphous high molecular polymer under a high temperature and a large external force for a long time. In some embodiments, the extruder may include a non-co-extrusion extruder and a co-extrusion extruder. The non-co-extrusion extruder may include a main extruder and a mold with a channel having a certain cross-sectional shape. The co-extrusion extruder may include a main extruder, an auxiliary extruder, a feeding device, a PLC control system, a distributor, and a mold with a channel having a certain cross-sectional shape, the feeding device being arranged on the main extruder, the main extruder being connected to the distributor through a confluent core channel, the auxiliary extruder being connected to the distributor through a confluent core channel, the distributor being connected to the mold, and the PLC control system being used to control the operation of the extruder and its supporting equipment. The co-extrusion extruder used in the embodiment of this specification is an existing co-extrusion extruder on the market, which will not be repeated here.

[0160] In some embodiments, the manufacturing method of the co-extruded stone-plastic layer through extrusion can be: the first mixed material is put into the main extruder and the auxiliary extruder on a co-extrusion extruder for plasticization and extrusion into the upper and lower flow channels of the distributor; then the second mixed material is put into another extruder to extrude the stone-plastic rigid layer into the middle flow channel of the distributor, thereby forming a multi-layer structure in the distributor, and then entering the mold; finally, in the mold, extrusion molding is performed to obtain a three-layer co-extruded stone-plastic layer.

[0161] In some embodiments, the extruded co-extruded stone plastic layer enters the calendering roller group for calendering and thickness determination, and then is laminated with the color film and wear-resistant layer, and the embossing roller embosses the texture in one step to obtain the stone plastic floor. The calendering roller group refers to a device that uses rollers to apply pressure to the material to produce texture. For example, the calendering roller group may include four rollers, five rollers, or six rollers. Calendering and thickness determination refers to determining the final thickness of the substrate after compacting and smoothing the surface of the extruded substrate. The embossing roller refers to a roller used to press concave and convex patterns onto the surface of an object. For the definition of the color film layer and the wear-resistant layer, please refer to Figure 2 Related description.

[0162] In some embodiments, the material of at least one of the first stabilization layer and the second stabilization layer, based on 363.5 parts by weight of the first stabilization layer or the second stabilization layer, may include 90-110 parts by weight of polyvinyl chloride, 10-15 parts by weight of ACR / nano-SiO2 composite particles, and at least one of the following materials: 210-270 parts by weight of inorganic filler, 0.9-1.5 parts by weight of polyethylene wax, 6-10 parts by weight of stabilizer, 0.8-1.4 parts by weight of stearic acid, 0.2-0.6 parts by weight of oxidized polyethylene wax, and 0.1-0.5 parts by weight of carbon black.

[0163] In some embodiments, based on 526.8 parts by weight of the stone plastic rigid layer, the material of the stone plastic rigid layer may include 90-110 parts by weight of polyvinyl chloride, 10-15 parts by weight of ACR / nano-SiO2 composite particles and at least one of the following materials: 360-425 parts by weight of inorganic filler, 1.2-1.8 parts by weight of polyethylene wax, 5-8 parts by weight of stabilizer, 1.0-1.6 parts by weight of stearic acid and 10-15 parts by weight of glass beads.

[0164] For more details on the composition of the first stabilizing layer, the second stabilizing layer, and the stone plastic rigid layer, see Figure 1 Related description in .

[0165] In some embodiments, the ACR grafting rate on the surface of the ACR / nano-SiO2 composite particles in the above materials can be 70-110%. For the definition of ACR grafting rate, please refer to Figure 1 Description.

[0166] In some embodiments, the second mixed material further comprises polyvinyl chloride. The first mixed material further comprises polyvinyl chloride. The amount of ACR / nano-SiO2 composite particles used is 10%-15% of the mass content of polyvinyl chloride in the corresponding mixed material.

[0167] In some embodiments, the amount of ACR / nano-SiO2 composite particles used can be 12.5% ​​of the mass content of polyvinyl chloride in the corresponding mixture. For more details on the amount of ACR / nano-SiO2 composite particles used to represent the mass content of polyvinyl chloride in the corresponding mixture, see Figure 1 Description.

[0168] The basic concepts have been described above. Obviously, for those skilled in the art, the above detailed disclosure is only for example and does not constitute a limitation of this specification. Although not explicitly stated here, those skilled in the art may make various modifications, improvements and corrections to this specification. Such modifications, improvements and corrections are suggested in this specification, so such modifications, improvements and corrections still belong to the spirit and scope of the exemplary embodiments of this specification.

[0169] At the same time, this specification uses specific words to describe the embodiments of this specification. For example, "one embodiment", "an embodiment", and / or "some embodiments" refer to a certain feature, structure or characteristic related to at least one embodiment of this specification. Therefore, it should be emphasized and noted that "one embodiment" or "an embodiment" or "an alternative embodiment" mentioned twice or more in different positions in this specification does not necessarily refer to the same embodiment. In addition, certain features, structures or characteristics in one or more embodiments of this specification can be appropriately combined.

[0170] In addition, unless explicitly stated in the claims, the order of the processing elements and sequences described in this specification, the use of alphanumeric characters, or the use of other names are not intended to limit the order of the processes and methods of this specification. Although the above disclosure discusses some invention embodiments that are currently considered useful through various examples, it should be understood that such details are only for illustrative purposes, and the attached claims are not limited to the disclosed embodiments. On the contrary, the claims are intended to cover all modifications and equivalent combinations that are consistent with the essence and scope of the embodiments of this specification. For example, although the system components described above can be implemented by hardware devices, they can also be implemented only by software solutions, such as installing the described system on an existing server or mobile device.

[0171] Similarly, it should be noted that in order to simplify the description disclosed in this specification and thus help understand one or more embodiments of the invention, in the above description of the embodiments of this specification, multiple features are sometimes combined into one embodiment, figure or description thereof. However, this disclosure method does not mean that the features required by the subject matter of this specification are more than the features mentioned in the claims. In fact, the features of the embodiments are less than all the features of the single embodiment disclosed above.

[0172] In some embodiments, numbers describing the number of components and attributes are used. It should be understood that such numbers used in the description of the embodiments are modified by the modifiers "about", "approximately" or "substantially" in some examples. Unless otherwise specified, "about", "approximately" or "substantially" indicate that the numbers are allowed to vary by ±20%. Accordingly, in some embodiments, the numerical parameters used in the specification and claims are approximate values, which may change according to the required features of individual embodiments. In some embodiments, the numerical parameters should take into account the specified significant digits and adopt the general method of retaining the digits. Although the numerical domains and parameters used to confirm the breadth of the range in some embodiments of this specification are approximate values, in specific embodiments, the setting of such numerical values ​​is as accurate as possible within the feasible range.

[0173] Each patent, patent application, patent application publication, and other materials, such as articles, books, specifications, publications, documents, etc., cited in this specification is hereby incorporated by reference in its entirety. Except for application history documents that are inconsistent with or conflicting with the contents of this specification, documents that limit the broadest scope of the claims of this specification (currently or later attached to this specification) are also excluded. It should be noted that if the descriptions, definitions, and / or use of terms in the materials attached to this specification are inconsistent or conflicting with the contents described in this specification, the descriptions, definitions, and / or use of terms in this specification shall prevail.

[0174] Finally, it should be understood that the embodiments described in this specification are only used to illustrate the principles of the embodiments of this specification. Other variations may also fall within the scope of this specification. Therefore, as an example and not a limitation, alternative configurations of the embodiments of this specification may be considered consistent with the teachings of this specification. Accordingly, the embodiments of this specification are not limited to the embodiments explicitly introduced and described in this specification.

Claims

1. A multi-layer co-extruded stone plastic floor, characterized in that: include: At least one co-extruded stone-plastic layer, the co-extruded stone-plastic layer comprising from top to bottom at least: a first stabilizing layer, a stone-plastic rigid layer, and a second stabilizing layer; The first stabilizing layer and the second stabilizing layer have a dimensional change rate of 0% to 0.12% at -15°C to 80°C; At least one of the first stabilizing layer, the stone-plastic rigid layer and the second stabilizing layer comprises ACR / nano-SiO2 composite particles; The stone plastic rigid layer further comprises polyvinyl chloride, at least one of the first stabilizing layer and the second stabilizing layer further comprises polyvinyl chloride, and the amount of the ACR / nano-SiO2 composite particles is 10%-15% of the mass content of the polyvinyl chloride in the corresponding layer; The stone plastic rigid layer further comprises glass microspheres, the amount of which is 10%-15% of the mass content of polyvinyl chloride in the stone plastic rigid layer, and the glass microspheres are modified hollow glass microspheres; Based on 526.8 parts by weight of the stone plastic rigid layer, the composition of the stone plastic rigid layer includes 10-15 parts by weight of the glass microspheres.

2. The multi-layer co-extruded stone plastic floor according to claim 1, characterized in that: The ACR grafting rate on the surface of the ACR / nano-SiO2 composite particles is 70%-110%.

3. The multi-layer co-extruded stone plastic floor according to claim 1, characterized in that: The co-extruded stone-plastic layer includes, from top to bottom, the first stabilizing layer, the stone-plastic rigid layer and the second stabilizing layer. The thickness ratio of the first stabilizing layer, the stone-plastic rigid layer and the second stabilizing layer is 1:1.8-2.2:

1.

4. The multi-layer co-extruded stone plastic floor according to claim 1, characterized in that: The mass content of polyvinyl chloride in the stone plastic rigid layer is 18%-21%.

5. The multi-layer co-extruded stone plastic floor according to claim 1, characterized in that: The mass content of polyvinyl chloride in at least one of the first stabilizing layer and the second stabilizing layer is 25%-30%.

6. The multi-layer co-extruded stone plastic floor according to claim 1, characterized in that: Based on 526.8 parts by weight of the stone-plastic rigid layer, the composition of the stone-plastic rigid layer includes 10-15 parts by weight of ACR / nano-SiO2 composite particles.

7. The multi-layer co-extruded stone plastic floor according to claim 1, characterized in that: Based on 526.8 parts by weight of the stone plastic rigid layer, the composition of the stone plastic rigid layer includes 90-110 parts by weight of the polyvinyl chloride and at least one of the following components: 360-425 parts by weight of inorganic filler, 1.2-1.8 parts by weight of polyethylene wax, 5-8 parts by weight of stabilizer, 1.0-1.6 parts by weight of stearic acid.

8. The multi-layer co-extruded stone plastic floor according to claim 1, characterized in that: Based on 363.5 parts by weight of the first stabilizing layer or the second stabilizing layer, the first stabilizing layer and the second stabilizing layer include 90-110 parts by weight of polyvinyl chloride, 10-15 parts by weight of ACR / nano-SiO2 composite particles, and at least one of the following components: 210-270 parts by weight of inorganic filler, 0.9-1.5 parts by weight of polyethylene wax, 6-10 parts by weight of stabilizer, 0.8-1.4 parts by weight of stearic acid, 0.2-0.6 parts by weight of oxidized polyethylene wax, and 0.1-0.5 parts by weight of carbon black.

9. The multi-layer co-extruded stone plastic floor according to claim 1, characterized in that: The multi-layer co-extruded stone-plastic floor also includes at least one of the following structural layers: a UV coating, a wear-resistant layer, and a color film layer.

10. A method for manufacturing a multi-layer co-extruded stone plastic floor according to any one of claims 1 to 9, characterized in that: The following steps are involved: Mixing materials of at least one of the first stabilization layer and the second stabilization layer to obtain a first mixed material, stirring the first mixed material to obtain a first batch, wherein the first mixed material contains ACR / nano-SiO2 composite particles; Mixing the materials of the stone-plastic rigid layer to obtain a second mixed material, stirring the second mixed material to obtain a second batch, wherein the second mixed material contains ACR / nano-SiO2 composite particles; The first mixed material and the second mixed material are extruded through an extruder to form a co-extruded stone-plastic layer. The co-extruded stone-plastic layer includes a three-layer structure, which includes the first stabilizing layer, the stone-plastic rigid layer and the second stabilizing layer from top to bottom.

11. The method for manufacturing a multi-layer co-extruded stone plastic floor according to claim 10, characterized in that: Based on 363.5 parts by weight of the first stabilizing layer or the second stabilizing layer, the materials of the first stabilizing layer or the second stabilizing layer include 90-110 parts by weight of polyvinyl chloride, 10-15 parts by weight of ACR / nano-SiO2 composite particles and at least one of the following materials: 210-270 parts by weight of inorganic filler, 0.9-1.5 parts by weight of polyethylene wax, 6-10 parts by weight of stabilizer, 0.8-1.4 parts by weight of stearic acid, 0.2-0.6 parts by weight of oxidized polyethylene wax and 0.1-0.5 parts by weight of carbon black.

12. The method for manufacturing a multi-layer co-extruded stone plastic floor according to claim 10, characterized in that: Based on 526.8 parts by weight of the stone-plastic rigid layer, the material of the stone-plastic rigid layer includes 90-110 parts by weight of polyvinyl chloride, 10-15 parts by weight of ACR / nano-SiO2 composite particles and at least one of the following materials: 360-425 parts by weight of inorganic filler, 1.2-1.8 parts by weight of polyethylene wax, 5-8 parts by weight of stabilizer, 1.0-1.6 parts by weight of stearic acid and 10-15 parts by weight of glass microspheres.

13. The method for manufacturing a multi-layer co-extruded stone plastic floor according to claim 10, characterized in that: The ACR grafting rate on the surface of the ACR / nano-SiO2 composite particles is 70%-110%.

14. The method for manufacturing a multi-layer co-extruded stone plastic floor according to claim 13, characterized in that: The second mixed material contains polyvinyl chloride, the first mixed material contains polyvinyl chloride, and the amount of the ACR / nano-SiO2 composite particles is 10%-15% of the mass content of the polyvinyl chloride in the corresponding mixed material.

Images