A flexible co-extruded wood-plastic flooring and its preparation method

Abstract

This invention provides an elastic co-extruded wood-plastic composite flooring, comprising, from top to bottom, an elastic layer, an adhesive layer, and a core layer. The elastic layer comprises the following raw materials in parts by weight: 25-35 parts TPE, 40-50 parts HDPE, 1-3 parts SiO2, 1-3 parts antioxidant, and 1-3 parts anti-aging agent. The adhesive layer comprises the following raw materials in parts by weight: 20-28 parts maleic anhydride-grafted polyethylene and 15-20 parts EVA. The core layer comprises the following raw materials in parts by weight: 30-40 parts hydrophobic treated wood flour, 10-15 parts nano-grade ultrafine calcium carbonate, and 40-60 parts HDPE. This invention also provides a method for preparing the above-mentioned flooring. The advantages of this flooring are: it not only provides a comfortable feel underfoot but also has a long service life and good resilience, making it suitable for indoor and outdoor sports venues.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of wood-plastic floor, in particular to an elastic co-extrusion wood-plastic floor and a preparation method thereof. BACKGROUND

[0002] With the improvement of living standards, people also pay more and more attention to sports. For some indoor and outdoor sports places, such as basketball, volleyball, badminton, table tennis and other project places, the rebound performance of the floor is required to be high. Good rebound elasticity can avoid injury when people accidentally fall down.

[0003] Wood-plastic composite material is a new type of material composed of wood fiber material and plastic, which has been widely used in the field of floor. However, the traditional wood-plastic floor also has some shortcomings, such as poor elasticity. If the traditional wood-plastic floor is directly used as an indoor and outdoor sports floor, the effect will be very unsatisfactory. SUMMARY

[0004] The technical problem to be solved by the present application is to provide an elastic co-extrusion wood-plastic floor suitable for indoor and outdoor sports places and a preparation method thereof.

[0005] The present application solves the above technical problems by adopting the following technical solutions:

[0006] An elastic co-extrusion wood-plastic floor, from top to bottom, includes an elastic layer, an adhesive layer and a core layer; the elastic layer includes the following raw materials in parts by weight: TPE 25-35 parts, HDPE 40-50 parts, SiO2 1-3 parts, antioxidant 1-3 parts, and anti-aging agent 1-3 parts; the adhesive layer includes the following raw materials in parts by weight: maleic anhydride grafted polyethylene 20-28 parts, EVA 15-20 parts; the core layer includes the following raw materials in parts by weight: hydrophobic treated wood powder 30-40 parts, nano ultrafine calcium carbonate 10-15 parts, and HDPE 40-60 parts.

[0007] As one of the preferred modes of the present application, in the elastic layer: the antioxidant is antioxidant GA-80.

[0008] As one of the preferred modes of the present application, in the elastic layer: the anti-aging agent includes 3-[3-(2-H-benzotriazole-2-yl)-4-hydroxy-5-tert-butyl phenyl]-propionic acid-polyethylene glycol 300 ester and 3,5-di-tert-butyl-4-hydroxyphenylpropionic acid isooctyl ester, and the mixing ratio is 1:1 by weight.

[0009] As one of the preferred modes of the present application, in the core layer: the hydrophobic treated wood powder is a composite modified wood powder, and the modification method is as follows:

[0010] The wood powder is dried at 90-100 DEG C until constant weight; 3% (mass percentage, percentage of the total mass of wood powder) of butyl methacrylate BMA and styrene St (BMA: St = 1:1) are uniformly sprayed in the form of fine mist on the surface of the wood powder, and the wood powder is stirred while spraying; after spraying, the wood powder is treated at 75-85 DEG C for 0.5-1.0 h.

[0011] As one of the preferred modes of the present application, the nanoscale ultrafine calcium carbonate in the core layer is calcium carbonate powder with a particle size of 1-100 nm.

[0012] As one of the preferred modes of the present application, the surface of the elastic layer of the elastic co-extrusion wood-plastic floor is further coated with a functional coating.

[0013] As one of the preferred modes of the present application, the functional coating comprises the following raw materials in parts by weight: 50-60 parts of epoxy resin emulsion, 1-2 parts of antioxidant GA-80, 1-2 parts of defoaming agent BYK-O70, 1-2 parts of leveling agent BYK-330, 1-2 parts of dispersing agent BYK-163, 0.6-0.9 parts of octylphenol polyoxyethylene ether, 0.1-0.5 parts of ethylenediamine, and 15-20 parts of water.

[0014] As one of the preferred modes of the present application, when the elastic co-extrusion wood-plastic floor is used indoors, the raw materials of the elastic layer and the core layer of the floor further comprise a synergistic flame-retardant system.

[0015] As one of the preferred modes of the present application, the intumescent flame retardant comprises 3-5 parts of vermiculite EVMT and 25-30 parts of intumescent flame retardant IFR.

[0016] A method for preparing the above-mentioned elastic co-extrusion wood-plastic floor, different melt streams of the elastic layer, the adhesive layer and the core layer are formed, combined in a compound head, stacked in three layers, co-extruded and passed through a rectangular die to obtain the target elastic co-extrusion wood-plastic floor.

[0017] As one of the preferred modes of the present application, after co-extrusion and passing through the rectangular die, a layer of functional coating is coated on the elastic layer of the floor.

[0018] The present application has the following advantages compared with the prior art:

[0019] (1) The surface layer of the floor is an elastic layer, and the main components are TPE, HDP, SiO2, antioxidant and anti-aging agent, which not only provides comfortable foot feeling, but also has the advantages of long service life and good resilience; the middle layer is an adhesive layer, mainly maleic anhydride grafted polyethylene and EVA, which can improve the adhesion between the elastic layer and the core layer; the core layer is hydrophobic treated wood powder, nanoscale ultrafine calcium carbonate and HDPE, which can improve the physical and mechanical properties of wood-plastic composite materials while reducing the water absorption of the floor.

[0020] (2) In the core layer of the flooring of the present invention, the “hydrophobic treated wood flour” is specifically modified with 3% butyl methacrylate (BMA) and styrene (St). After hydrophobic modification, the contact angle of WPC increases, the interfacial compatibility between wood flour and HDPE is improved, and the mechanical properties are significantly improved. Among them, when the addition amount of BMA and St is 3%, the mechanical properties of WPC are the best.

[0021] (3) The surface of the elastic layer of the present invention is also coated with a functional coating based on a specific formula; the coating has good anti-slip performance, and its static friction coefficient can reach 6.2, which is within the safe range; it has excellent weather resistance, which can effectively improve the service life of the coating; and it has good crack resistance.

[0022] (4) When the elastic co-extruded wood-plastic flooring of the present invention is used indoors, the elastic layer and core layer of the flooring also include a synergistic flame retardant system composed of vermiculite EVMT and IFR respectively; vermiculite EVMT has a good synergistic effect in the IFR flame retardant HDPE system, which can improve the flame retardant performance of the flooring.

[0023] (5) The preparation process of the present invention is simple, highly operable, and has good repeatability. Detailed Implementation

[0024] The embodiments of the present invention are described in detail below. These embodiments are implemented based on the technical solution of the present invention, and provide detailed implementation methods and specific operation processes. However, the scope of protection of the present invention is not limited to the following embodiments.

[0025] Example 1

[0026] This embodiment of an elastic co-extruded wood-plastic flooring includes, from top to bottom, an elastic layer, an adhesive layer, and a core layer.

[0027] The elastic layer comprises the following raw materials in parts by weight: 25 parts TPE, 40 parts HDPE, 1 part SiO2, 1 part antioxidant GA-80, 0.5 parts 3-[3-(2-H-benzotriazol-2-yl)-4-hydroxy-5-tert-butylphenyl]-propionic acid-polyethylene glycol 300, and 0.5 parts isooctyl 3,5-di-tert-butyl-4-hydroxyphenylpropionate. The adhesive layer comprises the following raw materials in parts by weight: 20 parts maleic anhydride-grafted polyethylene and 15 parts EVA. The core layer comprises the following raw materials in parts by weight: 30 parts hydrophobic treated wood flour, 10 parts nano-grade ultrafine calcium carbonate (1 nm), and 40 parts HDPE.

[0028] In this embodiment, the hydrophobic treated wood powder is a composite modified wood powder: the wood powder is dried at 90°C to constant weight; 3% (mass percentage, percentage of the total mass of the wood powder) of butyl methacrylate (BMA) and styrene (St) (BMA:St = 1:1) are sprayed evenly on the surface of the wood powder in a fine mist while the wood powder is stirred; after spraying, the wood powder is placed at 75°C for 1.0 h.

[0029] Flooring preparation method:

[0030] The elastic layer, adhesive layer, and core layer are formed into different molten material flows, which are then combined in a composite die head, co-extruded, and passed through a rectangular die to obtain the desired elastic co-extruded wood-plastic flooring.

[0031] Example 2

[0032] This embodiment of an elastic co-extruded wood-plastic flooring includes, from top to bottom, an elastic layer, an adhesive layer, and a core layer.

[0033] The elastic layer comprises the following raw materials in parts by weight: 35 parts TPE, 50 parts HDPE, 3 parts SiO2, 3 parts antioxidant GA-803, 1.5 parts 3-[3-(2-H-benzotriazol-2-yl)-4-hydroxy-5-tert-butylphenyl]-propionic acid-polyethylene glycol 300, and 1.5 parts isooctyl 3,5-di-tert-butyl-4-hydroxyphenylpropionate. The adhesive layer comprises the following raw materials in parts by weight: 28 parts maleic anhydride-grafted polyethylene and 20 parts EVA. The core layer comprises the following raw materials in parts by weight: 40 parts hydrophobic treated wood flour, 15 parts nano-grade ultrafine calcium carbonate (100nm), and 60 parts HDPE.

[0034] In this embodiment, the hydrophobic treated wood powder is a composite modified wood powder: the wood powder is dried at 100°C to constant weight; 3% (mass percentage, percentage of the total mass of the wood powder) of butyl methacrylate (BMA) and styrene (St) (BMA:St = 1:1) are sprayed evenly on the surface of the wood powder in a fine mist while the wood powder is stirred; after spraying, the wood powder is placed at 85°C for 0.5 hours.

[0035] Flooring preparation method:

[0036] The elastic layer, adhesive layer, and core layer are formed into different molten material flows, which are then combined in a composite die head, co-extruded, and passed through a rectangular die to obtain the desired elastic co-extruded wood-plastic flooring.

[0037] Example 3

[0038] This embodiment of an elastic co-extruded wood-plastic flooring includes, from top to bottom, an elastic layer, an adhesive layer, and a core layer.

[0039] The elastic layer comprises the following raw materials in parts by weight: 30 parts TPE, 45 parts HDPE, 2 parts SiO2, 2 parts antioxidant GA-802, 1 part 3-[3-(2-H-benzotriazol-2-yl)-4-hydroxy-5-tert-butylphenyl]-propionic acid-polyethylene glycol 300, and 1 part isooctyl 3,5-di-tert-butyl-4-hydroxyphenylpropionate. The adhesive layer comprises the following raw materials in parts by weight: 25 parts maleic anhydride-grafted polyethylene and 18 parts EVA. The core layer comprises the following raw materials in parts by weight: 35 parts hydrophobic treated wood flour, 12 parts nano-grade ultrafine calcium carbonate (50nm), and 50 parts HDPE.

[0040] In this embodiment, the hydrophobic treated wood powder is a composite modified wood powder: the wood powder is dried at 95°C to constant weight; 3% (mass percentage, percentage of the total mass of the wood powder) of butyl methacrylate (BMA) and styrene (St) (BMA:St = 1:1) are sprayed evenly on the surface of the wood powder in a fine mist while the wood powder is stirred; after spraying, the wood powder is placed at 80°C for 0.6 hours.

[0041] Flooring preparation method:

[0042] The elastic layer, adhesive layer, and core layer are formed into different molten material flows, which are then combined in a composite die head, co-extruded, and passed through a rectangular die to obtain the desired elastic co-extruded wood-plastic flooring.

[0043] Example 4

[0044] The elastic co-extruded wood-plastic flooring of this embodiment has the same structure and composition as that of embodiment 3, the main difference being that the elastic layer of the flooring is also coated with a functional coating.

[0045] The functional coating comprises the following raw materials in parts by weight: 50 parts epoxy resin emulsion, 1 part antioxidant GA-80, 1 part defoamer BYK-O70, 1 part leveling agent BYK-330, 1 part dispersant BYK-163, 0.6 parts octylphenol polyoxyethylene ether, 0.1 parts ethylenediamine, and 15 parts water.

[0046] Flooring preparation method:

[0047] The elastic layer, adhesive layer, and core layer are formed into different molten material flows, which are then combined in a composite die head, stacked, co-extruded, and passed through a rectangular die to obtain elastic co-extruded wood-plastic flooring; finally, a functional coating is applied to the elastic layer of the flooring.

[0048] Example 5

[0049] The elastic co-extruded wood-plastic flooring of this embodiment has the same structure and composition as that of embodiment 3, the main difference being that the elastic layer of the flooring is also coated with a functional coating.

[0050] The functional coating comprises the following raw materials in parts by weight: 60 parts epoxy resin emulsion, 2 parts antioxidant GA-80, 2 parts defoamer BYK-O70, 2 parts leveling agent BYK-330, 2 parts dispersant BYK-163, 0.9 parts octylphenol polyoxyethylene ether, 0.5 parts ethylenediamine, and 20 parts water.

[0051] Flooring preparation method:

[0052] The elastic layer, adhesive layer, and core layer are formed into different molten material flows, which are then combined in a composite die head, stacked, co-extruded, and passed through a rectangular die to obtain elastic co-extruded wood-plastic flooring; finally, a functional coating is applied to the elastic layer of the flooring.

[0053] Example 6

[0054] The elastic co-extruded wood-plastic flooring of this embodiment has the same structure and composition as that of embodiment 3, the main difference being that the elastic layer of the flooring is also coated with a functional coating.

[0055] The functional coating comprises the following raw materials in parts by weight: 55 parts epoxy resin emulsion, 1.5 parts antioxidant GA-80, 1.5 parts defoamer BYK-O70, 1.5 parts leveling agent BYK-330, 1.5 parts dispersant BYK-163, 0.8 parts octylphenol polyoxyethylene ether, 0.3 parts ethylenediamine, and 18 parts water.

[0056] Flooring preparation method:

[0057] The elastic layer, adhesive layer, and core layer are formed into different molten material flows, which are then combined in a composite die head, stacked, co-extruded, and passed through a rectangular die to obtain elastic co-extruded wood-plastic flooring; finally, a functional coating is applied to the elastic layer of the flooring.

[0058] Example 7

[0059] This embodiment provides an elastic co-extruded wood-plastic composite flooring, particularly suitable for indoor sports fields. Its structure and composition are basically the same as in Embodiment 3, with the main difference being that the elastic layer and core layer materials of the flooring also contain a synergistic flame-retardant system. The intumescent flame retardant comprises 3 parts vermiculite EVMT and 25 parts intumescent flame retardant IFR.

[0060] Example 8

[0061] This embodiment provides an elastic co-extruded wood-plastic composite flooring, particularly suitable for indoor sports fields. Its structure and composition are basically the same as in Embodiment 3, with the main difference being that the elastic layer and core layer materials of the flooring also contain a synergistic flame-retardant system. The intumescent flame retardant comprises 5 parts vermiculite EVMT and 30 parts intumescent flame retardant IFR.

[0062] Example 9

[0063] This embodiment provides an elastic co-extruded wood-plastic composite flooring, particularly suitable for indoor sports fields. Its structure and composition are basically the same as in Embodiment 3, with the main difference being that the elastic layer and core layer materials of the flooring also contain a synergistic flame-retardant system. The intumescent flame retardant includes vermiculite EVMT and intumescent flame retardant IFR.

[0064] Specifically, the elastic layer contains 3.5 parts vermiculite EVMT and 26 parts intumescent flame retardant IFR, and the core layer contains 4.5 parts vermiculite EVMT and 28 parts intumescent flame retardant IFR.

[0065] Experimental Example 1

[0066] This experiment was used to verify the effect of the elastic layer on the elastic properties of the elastic co-extruded wood-plastic flooring of the present invention (taking Examples 1, 2, and 3 as examples). The results are shown in Table 1.

[0067] Table 1. Influence of the elastic layer on the elastic properties of the elastic co-extruded wood-plastic flooring of the present invention.

[0068]

[0069] As shown in Table 2, the flooring of this invention has good elasticity and is suitable for indoor and outdoor sports venues.

[0070] Experiment Example 2

[0071] This experiment was used to demonstrate the effect of different hydrophobic treatment methods on the mechanical properties of the elastic co-extruded wood-plastic flooring of the present invention (based on the structure and raw materials of Example 3). The results are shown in Table 2.

[0072] Table 2. Effects of different hydrophobic treatment methods on the mechanical properties of the elastic co-extruded wood-plastic flooring of this invention.

[0073]

[0074]

[0075] According to the results in Table 2, the "hydrophobic wood flour" in the core layer of the flooring of the present invention is specifically modified with 3% butyl methacrylate (BMA) and styrene (St). After hydrophobic modification, the contact angle of WPC increases, the interfacial compatibility between wood flour and HDPE is improved, and the mechanical properties are optimal.

[0076] Experimental Example 3

[0077] This experiment is used to demonstrate the effect of adding functional coatings on the performance of the elastic co-extruded wood-plastic flooring of the present invention (taking Examples 3, 4, 5, and 6 as examples), and the results are shown in Table 3.

[0078] Table 3. Effects of functional coatings on the performance of the elastic co-extruded wood-plastic flooring of this invention.

[0079]

[0080] According to the results in Table 3, the surface of the elastic layer of the present invention is also coated with a functional coating based on a specific formula; the coating has good anti-slip performance, and its static friction coefficient can reach 6.2, which is within the safe range; it has excellent weather resistance and can effectively improve the service life of the coating.

[0081] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A resilient co-extruded wood plastic flooring, characterized in that, From top to bottom, it includes elastic layer, adhesive layer and core layer; the elastic layer includes the following raw materials in parts by weight: TPE 25-35 parts, HDPE 40-50 parts, SiO2 1-3 parts, antioxidant 1-3 parts, anti-aging agent 1-3 parts; the adhesive layer includes the following raw materials in parts by weight: maleic anhydride grafted polyethylene 20-28 parts, EVA 15-20 parts; the core layer includes the following raw materials in parts by weight: hydrophobic treated wood powder 30-40 parts, nano ultrafine calcium carbonate 10-15 parts, HDPE 40-60 parts; in the core layer: the hydrophobic treated wood powder is a composite modified wood powder, and the modification method is as follows: The wood powder is dried at 90-100℃ to constant weight; 3% of butyl methacrylate and styrene are uniformly sprayed in fine mist on the surface of the wood powder, and the wood powder is stirred while spraying; after spraying, the wood powder is treated at 75-85℃ for 0.5-1.0h.

2. The elastic co-extrusion wood plastic floor according to claim 1, characterized in that, In the elastic layer: the antioxidant is antioxidant GA-80.

3. The elastic co-extrusion wood plastic floor according to claim 1, characterized in that, In the elastic layer: the anti-aging agent includes 3-[3-(2-H-benzotriazole-2-yl)-4-hydroxy-5-tert-butylphenyl]-propionic acid-polyethylene glycol 300 ester and 3,5-di-tert-butyl-4-hydroxyphenylpropionic acid isooctyl ester, and the mixing ratio is 1:1 by weight.

4. The elastic co-extrusion wood plastic floor according to claim 1, wherein, The nano ultrafine calcium carbonate in the core layer is calcium carbonate powder with a particle size of 1-100nm.

5. The elastic co-extrusion wood plastic floor according to claim 1, wherein, The surface of the elastic layer of the elastic co-extrusion wood-plastic floor is also coated with functional coating.

6. The elastic co-extrusion wood plastic floor according to claim 5, characterized in that, The functional coating includes the following raw materials in parts by weight: epoxy resin emulsion 50-60 parts, antioxidant GA-80 1-2 parts, defoamer BYK-O70 1-2 parts, leveling agent BYK-330 1-2 parts, dispersant BYK-163 1-2 parts, octylphenol polyoxyethylene ether 0.6-0.9 parts, ethylenediamine 0.1-0.5 parts, water 15-20 parts.

7. The elastic co-extrusion wood-plastic floor according to any one of claims 1-6, characterized in that, When the elastic co-extrusion wood-plastic floor is used indoors, the raw materials of the elastic layer and the core layer of the floor also include a synergistic flame retardant system respectively.

8. A method for manufacturing the elastic co-extrusion wood plastic floor as claimed in any one of claims 1 to 7, characterized in that, The elastic layer, the adhesive layer and the core layer are formed into different melt streams, which are combined in one composite head, and then three layers are stacked, co-extruded and obtained through a rectangular die to obtain the target elastic co-extrusion wood-plastic floor.

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