A lightweight stone-crystal composite flooring with micro-foaming technology

Abstract

This invention belongs to the field of composite flooring technology and discloses a lightweight stone-crystal composite floor using a micro-foaming process. The flooring body comprises, from bottom to top, a substrate, a sound-absorbing layer, a heat-insulating layer, a wear-resistant layer, and a colored film. The angle between the front side and the bottom surface of the flooring body is 135°, and the angle between the rear side and the bottom surface is 45°. Multiple first protrusions are longitudinally and equidistantly fixed to the left side of the flooring body. This invention, by setting an inclined flooring body, first protrusions, first grooves, second protrusions, and second grooves, is more suitable for splicing. Furthermore, the limiting mechanism secures any two adjacent floorboards together. For disassembly, simply attach a suction cup to the upper surface of the flooring body and pull upwards at an angle. This simple and convenient method achieves the technical effect of individually disassembling any single floorboard, making it worthy of promotion.

Description

Technical Field

[0001] This invention relates to the field of composite flooring technology, specifically to a lightweight stone-crystal composite flooring using a micro-foaming process. Background Technology

[0002] Flooring, also known as engineered wood flooring, is the surface layer of a building's ground or floor, made of wood or other materials. Engineered wood flooring is a type of flooring that has its natural structure altered to achieve specific physical properties. It is made by cross-pressing different types of wood, thus overcoming the unidirectional isotropic properties of solid wood flooring. This results in lower shrinkage and expansion rates, better dimensional stability, and the preservation of the natural wood grain and comfortable feel of solid wood flooring.

[0003] Currently, composite flooring on the market is all in block form, available in different models and sizes. When laying the flooring, the ground needs to be leveled first, then the floorboards are laid one by one on the ground, and then the gaps between adjacent floorboards are filled with flooring adhesive. This kind of flooring installation process is very complicated and is prone to uneven gap width, affecting the appearance. Therefore, there is a need for a type of flooring that can be spliced, which can improve the efficiency of flooring installation and make the flooring more flat and beautiful.

[0004] To address the aforementioned issues, patent publication number CN212129787U discloses an environmentally friendly, sound-insulating, interlocking floor, comprising a floor body, a splicing groove on the left side of the floor body, and a splicing block fixedly connected to the right side of the floor body, wherein the splicing groove and the splicing block are adapted to each other; this patent achieves rapid installation and splicing of the floor through the mutual cooperation of the splicing groove and the splicing block.

[0005] While the aforementioned patent can solve the problem of floor splicing, the splicing method has certain limitations. When it is necessary to disassemble and replace a piece of flooring in a room, it can only be done by disassembling the outermost piece of flooring one by one towards the piece to be replaced, which increases the workload and reduces work efficiency.

[0006] To address these issues, we offer a lightweight stone-crystal composite flooring using a micro-foaming process. Summary of the Invention

[0007] The purpose of this invention is to solve the problems existing in the prior art and to propose a lightweight stone-crystal composite floor using a micro-foaming process.

[0008] To achieve the above objectives, the present invention provides the following technical solution: a lightweight stone-crystal composite floor using a micro-foaming process, comprising a floor body, wherein the floor body comprises, from bottom to top, a substrate, a sound-absorbing layer, a heat-insulating layer, a wear-resistant layer, and a colored film;

[0009] The angle between the front side and the lower end of the floor body is 135°, and the angle between the rear side and the lower end of the floor body is 45°. Multiple first protrusions are longitudinally and equidistantly fixed to the left side of the floor body, and multiple second protrusions are transversely and equidistantly fixed to the rear side of the floor body. The upper end faces of both the first and second protrusions are on the same plane as the upper end of the floor body, and the lower end faces of both the first and second protrusions are on the same plane as the lower end of the floor body. The angle between the front side of the first protrusion and the lower end of the floor body is 135°, and the angle between the rear side of the first protrusion and the upper end of the floor body is 45°. Multiple first grooves corresponding to the first protrusions are longitudinally and equidistantly opened to the right side of the floor body, and multiple second grooves corresponding to the second protrusions are transversely and equidistantly opened to the front side of the floor body. Limiting mechanisms for splicing are provided on the rear sides of both the first and second protrusions.

[0010] Preferably, the limiting mechanism includes a sliding groove formed on the rear side of the first protrusion and the second protrusion, a sliding plate slidably connected in the sliding groove, a limiting block fixedly connected to the rear side of the sliding plate, and a sliding rod fixedly connected to the center of the front side of the sliding plate.

[0011] Preferably, a return spring is sleeved on the outer side of the sliding rod, one end of the return spring is fixedly connected to the front side of the sliding plate, and the other end of the return spring is fixedly connected to the bottom surface of the sliding groove.

[0012] Preferably, the limiting block has a hemispherical structure, and limiting grooves are provided on the rear side of both the first groove and the second groove. The limiting groove on the rear side of the first groove is adapted to the limiting block on the first protrusion, and the limiting groove on the rear side of the second groove is adapted to the limiting block on the second protrusion.

[0013] Preferably, a joint is provided at the outer contour of the upper end face of the floor body and the first protrusion, the first groove, the second protrusion, and the second groove.

[0014] Preferably, a glue reservoir is provided below the grout opening, the shape of the glue reservoir is consistent with the shape of the grout opening, a push plate is slidably connected inside the glue reservoir, the top of the push plate is filled with grout, and a sealing film for sealing the grout is fixedly connected to the opening of the glue reservoir.

[0015] Preferably, both the first protrusion and the second protrusion have movable cavities. A connecting rod is fixedly connected to the lower end face of the push plate. The end of the connecting rod away from the push plate passes through the movable cavity and is fixedly connected to a second push block. The end of the sliding rod away from the sliding plate passes through the movable cavity and is fixedly connected to a first push block.

[0016] Preferably, the connecting rod and the sliding rod are arranged perpendicularly, and both the first push block and the second push block are right-angled trapezoidal structures, with the contact surfaces of the first push block and the second push block being inclined surfaces.

[0017] Preferably, a first magnet is fixedly connected to the upper end face of the second push block, and a second magnet that cooperates with the second magnet is fixedly connected to one side of the movable cavity corresponding to the first magnet.

[0018] Preferably, the substrate, sound-absorbing layer, heat-insulating layer, wear-resistant layer, and color film are compounded by high-temperature extrusion using a screw extruder, and the raw materials of the substrate contain a foaming agent.

[0019] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0020] 1. This invention, by setting an inclined floor body, a first protrusion, a first groove, a second protrusion, and a second groove, is more suitable for splicing. By using the limiting mechanism, any two adjacent base plates can be fixed together. When disassembling, simply attach the suction cup to the upper surface of the floor body and then pull it upwards at an angle. It is simple and convenient, and achieves the technical effect of being able to disassemble any floor piece individually. It is worth promoting.

[0021] 2. This invention utilizes a limiting mechanism, a first push block, a movable cavity, a connecting rod, a push plate, sealant, a sealing film, and a sealant opening. During the process of adjacent floorboards interlocking, the push plate is lifted upwards, thereby squeezing the sealant out of the storage tank and evenly filling the sealant opening. This achieves the technical effect of automatically filling the sealant, which is more time-saving and labor-saving than traditional technology and greatly improves work efficiency.

[0022] 3. In this invention, the substrate is extruded by a twin-screw extruder. Before extruding the substrate, a certain amount of foaming agent is added to the raw material formula. Then, the sound-absorbing layer, heat-insulating layer, wear-resistant layer and color film are laminated onto the substrate using the high temperature of the extruder, thereby forming a micro-foamed composite floor. This floor has a lower density and lighter material than traditional stone crystal floor, which saves costs in terms of transportation. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of the overall structure of the present invention;

[0024] Figure 2 This is a schematic diagram of the structure of the first protrusion, the first groove, the second protrusion, and the second groove in this invention;

[0025] Figure 3 This is a front view of the present invention;

[0026] Figure 4 This is a reverse side view of the invention;

[0027] Figure 5 for Figure 1 A magnified schematic diagram of the structure at center A;

[0028] Figure 6 for Figure 2 Enlarged schematic diagram of the structure at point B;

[0029] Figure 7 This is a cross-sectional view of the first protrusion in this invention.

[0030] In the diagram: 1. Floor body; 2. First protrusion; 3. First groove; 4. Grout joint; 5. Sliding groove; 6. Sliding rod; 7. Sliding plate; 8. Limiting block; 9. Return spring; 10. First push block; 11. Movable cavity; 12. Second push block; 13. Connecting rod; 14. Push plate; 15. Grout; 16. Sealing film; 17. Adhesive storage tank; 18. Substrate; 19. Sound-absorbing layer; 20. Thermal insulation layer; 21. Wear-resistant layer; 22. Color film; 23. Limiting groove; 24. Second protrusion; 25. Second groove; 26. First magnet; 27. Second magnet. Detailed Implementation

[0031] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0032] Please refer to Figures 1-7 A lightweight stone-crystal composite floor using a micro-foaming process includes a floor body 1. From bottom to top, the floor body 1 comprises a substrate 18, a sound-absorbing layer 19, a heat-insulating layer 20, a wear-resistant layer 21, and a colored film 22. The substrate 18, sound-absorbing layer 19, heat-insulating layer 20, wear-resistant layer 21, and colored film 22 are formed by high-temperature extrusion using a screw extruder. The raw materials of the substrate 18 contain a foaming agent. After mixing with the foaming agent, the substrate 18 has a lower density and is lighter than traditional stone-crystal flooring, thus saving significant transportation costs. The high-temperature extrusion using a screw extruder further enhances the performance of the floor body 1.

[0033] The angle between the front side and the lower end of the floor body 1 is 135°, and the angle between the rear side and the lower end of the floor body 1 is 45°. Multiple first protrusions 2 are fixedly connected longitudinally at equal intervals on the left side of the floor body 1, and multiple second protrusions 24 are fixedly connected laterally at equal intervals on the rear side of the floor body 1. The upper end of both the first protrusions 2 and the second protrusions 24 are on the same plane as the upper end of the floor body 1, and the lower end of both the first protrusions 2 and the second protrusions 24 are on the same plane as the lower end of the floor body 1. The angle between the front side of the first protrusion 2 and the lower end of the floor body 1 is 135°, and the angle between the rear side of the first protrusion 2 and the upper end of the floor body 1 is 45°. Multiple first grooves 3 corresponding to the first protrusions 2 are longitudinally equidistantly provided on the right side of the floor body 1, and multiple second grooves 25 corresponding to the second protrusions 24 are laterally equidistantly provided on the front side of the floor body 1. Limiting mechanisms for splicing are provided on the rear sides of both the first protrusions 2 and the second protrusions 24.

[0034] This solution sets the floor body 1, the first protrusion 2, and the second protrusion 24 in an inclined position, which makes it easier to install and disassemble. During installation, the floor body 1 is laid flat on the ground and then pushed by hand so that the second protrusion 24 on the floor body 1 being installed engages with the second groove 25 of the floor body 1 behind it. At the same time, the first protrusion 2 on the floor body 1 being installed engages with the first groove 3 of the floor body 1 on the left. When pushing, the direction of force is always consistent with the inclination direction of the second push block 12. Then, the limiting mechanism is used to fix any two adjacent floor bodies 1 together, thereby realizing the rapid splicing and stable fixing of the composite floor.

[0035] During disassembly, a suction cup is used to adhere to the upper surface of the floor body 1, and then it is pulled upwards at an angle to disengage the first protrusion 2 and the second protrusion 24 from the corresponding first groove 3 and the second groove 25 without affecting the state of the adjacent floor bodies 1. This enables the rapid disassembly of individual floorboards, avoiding the need to disassemble each floorboard from the edge to the floorboards to be replaced in the prior art. This reduces labor intensity and improves work efficiency.

[0036] It is worth noting that after the multiple floor panels 1 are spliced ​​together, the first protrusion 2 and the first groove 3, and the second protrusion 24 and the second groove 25 cooperate with each other, so that two adjacent floor panels 1 can be interlocked. The rear floor panel 1 always presses down on the front floor panel 1. When a person steps on any floor panel, the floor can transmit the pressure to the floor panels on both sides and in front, thereby reducing the force on a single floor panel and helping to extend the service life of the composite floor.

[0037] Please refer to Figure 2 and Figure 7The limiting mechanism includes a sliding groove 5 formed on the rear side of the first protrusion 2 and the second protrusion 24. A sliding plate 7 is slidably connected in the sliding groove 5. A limiting block 8 is fixedly connected to the rear side of the sliding plate 7. A sliding rod 6 is fixedly connected to the center of the front side of the sliding plate 7. A return spring 9 is sleeved on the outer side of the sliding rod 6. One end of the return spring 9 is fixedly connected to the front side of the sliding plate 7, and the other end of the return spring 9 is fixedly connected to the bottom surface of the sliding groove 5. The limiting block 8 is a hemispherical structure. Limiting grooves 23 are formed on the rear side of both the first groove 3 and the second groove 25. The limiting groove 23 on the rear side of the first groove 3 is adapted to the limiting block 8 on the first protrusion 2. The limiting groove 23 on the rear side of the second groove 25 is adapted to the limiting block 8 on the second protrusion 24.

[0038] During the flooring installation process, as the first protrusion 2 slowly inserts into the corresponding first groove 3 and the second protrusion 24 slowly inserts into the corresponding second groove 25, the limiting block 8 is compressed, thereby pushing the sliding plate 7 to slide within the sliding rod 6. At the same time, the return spring 9 is compressed. When the first protrusion 2 and the first groove 3, and the second protrusion 24 and the second groove 25 are stably engaged, the limiting block 8 moves to the position of the limiting groove 23. At this time, the return spring 9 resets, causing the sliding plate 7 to rebound, thereby pushing the limiting block 8 into the limiting groove 23 on the first groove 3 and the second groove 25, thus limiting the flooring and making the installation of the flooring more stable and secure.

[0039] Please refer to Figure 1 , Figure 5 and Figure 6 A grout opening 4 is provided on the outer contour of the upper end face of the floor body 1 and the first protrusion 2, the first groove 3, the second protrusion 24, and the second groove 25;

[0040] The purpose of setting the grout joint 4 is to facilitate the later grouting process, thereby further improving the waterproof and moisture-proof performance of the composite flooring and helping to extend its service life.

[0041] Please refer to Figure 7 A glue reservoir 17 is provided below the grout opening 4. The shape of the glue reservoir 17 is consistent with that of the grout opening 4. A push plate 14 is slidably connected inside the glue reservoir 17. The top of the push plate 14 is filled with grout 15. A sealing film 16 for sealing the grout 15 is fixedly connected to the opening of the glue reservoir 17.

[0042] When the push plate 14 moves diagonally upward, it pushes the sealant 15 above the push plate 14 upward, eventually breaking through the sealing film 16 on the top surface, so that the sealant 15 is evenly filled into the sealant opening 4. This avoids the phenomenon of manually filling the sealant in the existing technology, reduces labor intensity, and helps to improve work efficiency.

[0043] Please refer to Figure 7Both the first protrusion 2 and the second protrusion 24 have movable cavities 11. The lower end face of the push plate 14 is fixedly connected to a connecting rod 13. The end of the connecting rod 13 away from the push plate 14 passes through the movable cavity 11 and is fixedly connected to a second push block 12. The end of the sliding rod 6 away from the sliding plate 7 passes through the movable cavity 11 and is fixedly connected to a first push block 10. The connecting rod 13 and the sliding rod 6 are arranged perpendicularly. The first push block 10 and the second push block 12 are both right-angled trapezoidal structures. The contact surfaces of the first push block 10 and the second push block 12 are both inclined. The upper end face of the second push block 12 is fixedly connected to a first magnet 26. Inside the movable cavity 11, on the side corresponding to the first magnet 26, a second magnet 27 that cooperates with the first magnet 26 is fixedly connected.

[0044] When the limiting block 8 is squeezed, it will push the sliding rod 6 to move away from the limiting block 8, thereby pushing the first push block 10 to move in the movable cavity 11. Since the contact surface between the first push block 10 and the second push block 12 is inclined, the second push block 12 is pushed to move obliquely upward in the first push block 10, and then the push plate 14 is lifted by the connecting rod 13 to achieve the technical effect of automatically extruding the sealant 15. At the same time, the first magnet 26 and the second magnet 27 attract each other to prevent the second push block 12 from also resetting after the reset spring 9 resets and drives the first push block 10 to rebound, which would cause the sealant 15 to flow back, thus ensuring the stability of filling the sealant 15.

[0045] Working principle: In the production of composite flooring, a certain amount of foaming agent is first added to the raw materials of the substrate 18 and mixed thoroughly. The substrate 18 is then extruded using a twin-screw extruder. Then, the high temperature of the extruder is used to sequentially laminate the sound-absorbing layer 19, the heat-insulating layer 20, the wear-resistant layer 21, and the color film 22 onto the surface of the substrate 18, thereby forming the floor body 1. This makes the floor body 1 less dense, lighter, and easier to transport.

[0046] When laying composite flooring, first place the flooring body 1 flat on the ground, then push it by hand so that the second protrusion 24 on the flooring body 1 being installed engages with the second groove 25 of the flooring body 1 behind it. At the same time, the first protrusion 2 on the flooring body 1 being installed engages with the first groove 3 of the flooring body 1 on the left. When pushing, always ensure that the direction of force is consistent with the tilt direction of the second push block 12. As the first protrusion 2 slowly inserts into the corresponding first groove 3, the second protrusion 24 slowly inserts into the corresponding second groove 25. The limiting block 8 is squeezed, thereby pushing the sliding plate 7 to slide in the sliding rod 6. At the same time, the return spring 9 is compressed. When the first protrusion 2 and the first groove 3, and the second protrusion 24 and the second groove 25 are stably engaged, the limiting block 8 just moves to the position of the limiting groove 23. At this time, the return spring 9 resets and drives the sliding plate 7 to rebound, thereby pushing the limiting block 8 into the limiting groove 23 on the first groove 3 and the second groove 25, realizing the limiting of the flooring, making the installation of the flooring more stable and firm.

[0047] At the same time, when the limiting block 8 is squeezed, it will push the sliding rod 6 to move away from the limiting block 8, thereby pushing the first push block 10 to move in the active cavity 11. Since the contact surface between the first push block 10 and the second push block 12 is inclined, the second push block 12 is pushed to move obliquely upward in the first push block 10, and then the push plate 14 is lifted by the connecting rod 13 to achieve the technical effect of automatically extruding the sealant 15. At the same time, the first magnet 26 and the second magnet 27 attract each other to prevent the second push block 12 from also resetting after the reset spring 9 resets and drives the first push block 10 to rebound, which would cause the sealant 15 to flow back.

[0048] When disassembling the composite flooring, a suction cup is used to adhere to the upper surface of the flooring body 1, and then it is pulled upwards at an angle to disengage the first protrusion 2 and the second protrusion 24 from the corresponding first groove 3 and the second groove 25 without affecting the state of the adjacent flooring bodies 1, thereby achieving the rapid disassembly of a single flooring.

[0049] While embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions, and variations may be made to these embodiments without departing from the principles and spirit of the invention, and that the scope of the invention is defined by the appended claims and their equivalents.

Claims

1. A lightweight stone-crystal composite flooring using a micro-foaming process, comprising a flooring body (1), characterized in that: The floor body (1) consists of, from bottom to top, a substrate (18), a sound-absorbing layer (19), a heat-insulating layer (20), a wear-resistant layer (21), and a colored film (22). The angle between the front side and the lower end of the floor body (1) is 135°, and the angle between the rear side and the lower end of the floor body (1) is 45°. Multiple first protrusions (2) are longitudinally and equidistantly fixed to the left side of the floor body (1), and multiple second protrusions (24) are transversely and equidistantly fixed to the rear side of the floor body (1). The upper end faces of both the first protrusions (2) and the second protrusions (24) are on the same plane as the upper end face of the floor body (1), and the lower end faces of both the first protrusions (2) and the second protrusions (24) are aligned with the lower end face of the floor body (1). On the same plane, the angle between the front side of the first protrusion (2) and the lower end face of the floor body (1) is 135°, and the angle between the rear side of the first protrusion (2) and the upper end face of the floor body (1) is 45°. The right side of the floor body (1) is provided with a plurality of first grooves (3) corresponding to the first protrusion (2) at equal intervals in the longitudinal direction. The front side of the floor body (1) is provided with a plurality of second grooves (25) corresponding to the second protrusion (24) at equal intervals in the transverse direction. The rear sides of the first protrusion (2) and the second protrusion (24) are provided with a limiting mechanism for splicing. The limiting mechanism includes a sliding groove (5) formed on the rear side of the first protrusion (2) and the second protrusion (24), a sliding plate (7) is slidably connected in the sliding groove (5), a limiting block (8) is fixedly connected to the rear side of the sliding plate (7), and a sliding rod (6) is fixedly connected to the center of the front side of the sliding plate (7). The floor body (1) and the outer contour of the upper end face of the first protrusion (2), the first groove (3), the second protrusion (24), and the second groove (25) are provided with a grout opening (4); A glue reservoir (17) is provided below the grout opening (4). The shape of the glue reservoir (17) is consistent with that of the grout opening (4). A push plate (14) is slidably connected inside the glue reservoir (17). The top of the push plate (14) is filled with grout (15). A sealing film (16) for sealing the grout (15) is fixedly connected to the opening of the glue reservoir (17). Both the first protrusion (2) and the second protrusion (24) have movable cavities (11). The lower end face of the push plate (14) is fixedly connected to a connecting rod (13). The end of the connecting rod (13) away from the push plate (14) passes through the movable cavity (11) and is fixedly connected to a second push block (12). The end of the sliding rod (6) away from the sliding plate (7) passes through the movable cavity (11) and is fixedly connected to a first push block (10). The connecting rod (13) and the sliding rod (6) are arranged perpendicularly. The first push block (10) and the second push block (12) are both right-angled trapezoidal structures. The contact surfaces of the first push block (10) and the second push block (12) are both inclined surfaces. The raw materials of the substrate (18) contain a foaming agent.

2. The lightweight stone-crystal composite flooring using a micro-foaming process according to claim 1, characterized in that: A reset spring (9) is sleeved on the outer side of the sliding rod (6). One end of the reset spring (9) is fixedly connected to the front side of the sliding plate (7), and the other end of the reset spring (9) is fixedly connected to the inner bottom surface of the sliding groove (5).

3. The lightweight stone-crystal composite flooring with micro-foaming process according to claim 2, characterized in that: The limiting block (8) is a hemispherical structure. The first groove (3) and the second groove (25) are both provided with limiting grooves (23). The limiting groove (23) on the rear side of the first groove (3) is adapted to the limiting block (8) on the first protrusion (2). The limiting groove (23) on the rear side of the second groove (25) is adapted to the limiting block (8) on the second protrusion (24).

4. The lightweight stone-crystal composite flooring using a micro-foaming process according to claim 1, characterized in that: The upper end face of the second push block (12) is fixedly connected to a first magnet (26), and the side of the active cavity (11) corresponding to the first magnet (26) is fixedly connected to a second magnet (27) that cooperates with the first magnet (26).

5. The lightweight stone-crystal composite flooring using a micro-foaming process according to claim 1, characterized in that: The substrate (18), sound-absorbing layer (19), heat-insulating layer (20), wear-resistant layer (21) and color film (22) are compounded by high-temperature extrusion using a screw extruder.

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