A wood-plastic co-extruded floor and preparation method thereof

Abstract

A wood-plastic co-extruded floor comprises a core layer and a surface layer covering the core layer. The raw materials for preparing the plastic outer layer comprise, by weight, 30-50% HDPE, 20-40% PP, 20-30% elastomer and 10-15% functional additive. The invention avoids the occurrence of burrs, whitening and the like on the floor during sanding by adding a certain amount of elastomer to the raw materials of the floor surface layer.

Description

Technical Field

[0001] The invention belongs to the technical field of building decoration materials, and particularly relates to a wood-plastic co-extruded floor and a preparation method thereof. Background Art

[0002] Wood-plastic composites (WPC) are materials or products made by compounding or further processing one or more cellulose materials and one or more thermoplastic plastics through plastic processing technology. They have the advantages of anti-corrosion, moisture-proof, partial degradability, low environmental pollution, low cost, low water absorption, excellent mechanical properties, anti-aging, good dimensional stability, no cracking, etc., and have similar processability to wood. They can be widely used in building materials, furniture, logistics packaging and other industries. The surface of the second-generation co-extruded product is coated with a pure plastic functional layer. In order to cover up the plastic feeling of the product surface, an embossing process is generally used to make the surface of the second-generation co-extruded wood-plastic product have the wood texture of the original wood. However, when sanding the surface of the product, it will cause burrs and whitening on the surface of the product, which seriously affects the quality of the product.

[0003] For example, the invention patent application document with patent application number CN202010382104.9 discloses a polymer co-extruded wood plastic floor, including a surface layer and a core layer, wherein the surface layer is coated on the surface of the core layer, and the surface layer includes the following raw materials in parts by weight: 50-55 parts of wood powder, 20-25 parts of polyethylene recycled material, 10-15 parts of polypropylene new material, 6-12 parts of surface layer additives, 1.5-2.5 parts of compatibilizer, and 3-5 parts of pigment; the core layer includes the following raw materials in parts by weight: 50-55 parts of wood powder, 20-25 parts of polyethylene recycled material, 5-10 parts of polypropylene recycled material, 11.5-17.5 parts of core layer additives, and 1.5-2.5 parts of compatibilizer. During the processing of the above polymer co-extruded wood plastic floor, especially when the surface is sanded, the surface will still show whitening, burrs, etc., which will seriously reduce the quality of the floor. Summary of the invention

[0004] In order to solve the above-mentioned technical problems existing in the prior art, the present invention provides a wood-plastic co-extruded floor and a preparation method thereof. The present invention avoids the phenomenon of burrs and whitening on the floor surface during sanding by adding a certain amount of elastomer to the surface material of the co-extruded floor.

[0005] The specific technical solutions of the present invention are as follows:

[0006] A wood-plastic co-extruded floor comprises a core layer and a surface layer covering the core layer. The raw materials for preparing the surface layer comprise, by weight: 30-50% HDPE, 20-40% PP, 20-30% elastomer and 10-15% functional additive.

[0007] In the prior art, the surface of the second-generation co-extruded plastic wood floor has a wood texture. After extrusion, the floor surface needs to be sanded to make the surface of the plastic wood floor smoother and improve the cleanability of the floor surface. However, the outer layer of ordinary plastic material will appear white and have burrs during sanding. The whitening and burrs will affect the appearance of the floor and the cleaning effect of the floor surface.

[0008] In the above technical solution of the present application, by adjusting the surface material of the plastic wood floor, the surface burrs and whitening of the board surface during the sanding process are avoided to a great extent. When the content of the elastomer is 20-30%, the impact of sanding the floor surface with a 500-mesh sanding wheel is minimal, and no burrs or whitening will occur. When the sanding wheel is in contact with the wood-plastic surface, it will apply a friction force parallel to the contact surface of the two to the surface of the wood-plastic floor. The friction force has a certain impact on the floor surface parallel to the floor surface, and the impact may cause the surface of the surface layer to separate from the inside of the plastic, thereby causing the surface of the surface layer to separate from the inside of the plastic. As for the phenomena such as whitening and burrs, the inventors believe that this is caused by the weak impact resistance of the surface plastic. When rubbed by the sanding wheel, the surface of the plastic will separate from the inside of the plastic, and then whitening and burrs will occur. The surface plastic can be modified by adding elastomers to the surface components of the board. The added elastomer can form elastic crystals in the plastic to improve the impact resistance of the mixture of PP and HDPE. During sanding, the elastic crystals formed by the elastomer will form elastic buffers for the impact parallel to the floor surface caused by the friction impact. Under the buffering effect, the impact of the sanding wheel on the floor surface will not cause whitening, burrs and other phenomena on the floor surface.

[0009] As a preferred embodiment of the above technical solution of the present invention, the elastomer is selected from one or more of SEBS, SEB, TPU and POE.

[0010] The functional additives preferably described in the above technical solution of the present invention at least include antioxidants, light stabilizers, ultraviolet absorbers, lubricants and compatibilizers.

[0011] As a preferred functional auxiliary agent of the above technical solution of the present invention, it also includes a mildew preventer.

[0012] As a preferred raw material for preparing the core layer of the technical solution of the present invention, the raw materials include 40-60% PE, 25-45% fiber powder, 1-5% lubricant, and 2-5% processing aid.

[0013] Another object of the present invention is to provide a method for preparing a wood-plastic co-extruded floor, comprising the following steps:

[0014] S1, mixing and granulating the core layer material to obtain a core layer granular material;

[0015] S2, mixing and granulating the surface material to obtain the surface granular material;

[0016] S3, co-extruding the core layer granular material in step S1 and the surface layer granular material obtained in step S2 to obtain a coarse co-extruded floor;

[0017] S4, sanding the rough co-extruded floor obtained in step S3 to obtain a fine co-extruded floor;

[0018] S5, hot pressing the fine co-extruded floor, and then placing it for curing to obtain the wood-plastic co-extruded floor.

[0019] In the above technical solution of the present invention, by performing heat pressing treatment on the floor after sanding, the surface stress generated by the floor during the sanding process is eliminated, thereby improving the friction resistance, scratch resistance, stain resistance and weather resistance of the floor during daily use.

[0020] As a preferred embodiment of the above technical solution of the present invention, in step S5, the hot pressing process is completed by a pair of hot pressing rollers.

[0021] As a preferred embodiment of the above technical solution of the present invention, the temperature of the hot pressing roller is at least 120-150° C.; and the processing time is 1-10 minutes.

[0022] In summary, the beneficial effects of the present invention are as follows:

[0023] 1. The present invention improves the phenomenon of burrs and whitening of the floor during the sanding process by adding a certain amount of elastomer to the surface material of the floor;

[0024] 2. The present invention adopts HDPE and PP mixed plastic as the outer layer of the floor, which improves the impact resistance of the floor and also improves the foot feel of the floor;

[0025] 3. In the production process, the present invention eliminates the surface stress of the floor during the sanding process by heat treating the floor, thereby improving the wear resistance, scratch resistance, stain resistance and weather resistance of the floor surface. DETAILED DESCRIPTION

[0026] In order to make the technical problems, technical solutions and beneficial effects solved by the present invention more clearly understood, the present invention is further described in detail below in conjunction with the embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention.

[0027] Example 1

[0028] A wood-plastic co-extruded floor comprises a core layer and a surface layer covering the core layer. The raw materials for preparing the surface layer include, by weight: 30% HDPE, 40% PP, 20% elastomer and 10% functional additive.

[0029] The elastomer is selected from one or more of SEBS, SEB, TPU and POE.

[0030] The functional additives at least include antioxidants, light stabilizers, ultraviolet absorbers, lubricants and compatibilizers.

[0031] The functional additives also include mildew inhibitors.

[0032] The raw materials for preparing the core layer include 60% PE, 30% fiber powder, 5% lubricant and 5% processing aid.

[0033] The method for preparing the wood-plastic co-extruded floor comprises the following steps:

[0034] S1, mixing and granulating the core layer material to obtain a core layer granular material;

[0035] S2, mixing and granulating the surface material to obtain the surface granular material;

[0036] S3, co-extruding the core layer granular material in step S1 and the surface layer granular material obtained in step S2 to obtain a coarse co-extruded floor;

[0037] S4, sanding the rough co-extruded floor obtained in step S3 to obtain a fine co-extruded floor;

[0038] S5, hot pressing the fine co-extruded floor, and then placing it for curing to obtain the wood-plastic co-extruded floor.

[0039] In step S5, the hot pressing process is completed by a pair of hot pressing rollers.

[0040] The temperature of the hot pressing roller is at least 130°C; the processing time is 1 minute.

[0041] Example 2

[0042] A wood-plastic co-extruded floor comprises a core layer and a surface layer covering the core layer. The raw materials for preparing the surface layer include, by weight: 35% HDPE, 30% PP, 25% elastomer and 10% functional additive.

[0043] The elastomer is selected from one or more of SEBS, SEB, TPU and POE.

[0044] The functional additives at least include antioxidants, light stabilizers, ultraviolet absorbers, lubricants and compatibilizers.

[0045] The functional additives also include mildew inhibitors.

[0046] The raw materials for preparing the core layer include 60% PE, 30% fiber powder, 5% lubricant and 5% processing aid.

[0047] The method for preparing the wood-plastic co-extruded floor comprises the following steps:

[0048] S1, mixing and granulating the core layer material to obtain a core layer granular material;

[0049] S2, mixing and granulating the surface material to obtain the surface granular material;

[0050] S3, co-extruding the core layer granular material in step S1 and the surface layer granular material obtained in step S2 to obtain a coarse co-extruded floor;

[0051] S4, sanding the rough co-extruded floor obtained in step S3 to obtain a fine co-extruded floor;

[0052] S5, hot pressing the fine co-extruded floor, and then placing it for curing to obtain the wood-plastic co-extruded floor.

[0053] In step S5, the hot pressing process is completed by a pair of hot pressing rollers.

[0054] The temperature of the hot pressing roller is at least 130°C; the processing time is 1 minute.

[0055] Example 3

[0056] A wood-plastic co-extruded floor comprises a core layer and a surface layer covering the core layer. The raw materials for preparing the surface layer include, by weight: 30% HDPE, 30% PP, 30% elastomer and 10% functional additive.

[0057] The elastomer is selected from one or more of SEBS, SEB, TPU and POE.

[0058] The functional additives at least include antioxidants, light stabilizers, ultraviolet absorbers, lubricants and compatibilizers.

[0059] The functional additives also include mildew inhibitors.

[0060] The raw materials for preparing the core layer include 60% PE, 30% fiber powder, 5% lubricant and 5% processing aid.

[0061] The method for preparing the wood-plastic co-extruded floor comprises the following steps:

[0062] S1, mixing and granulating the core layer material to obtain a core layer granular material;

[0063] S2, mixing and granulating the surface material to obtain the surface granular material;

[0064] S3, co-extruding the core layer granular material in step S1 and the surface layer granular material obtained in step S2 to obtain a coarse co-extruded floor;

[0065] S4, sanding the rough co-extruded floor obtained in step S3 to obtain a fine co-extruded floor;

[0066] S5, hot pressing the fine co-extruded floor, and then placing it for curing to obtain the wood-plastic co-extruded floor.

[0067] In step S5, the hot pressing process is completed by a pair of hot pressing rollers.

[0068] The temperature of the hot pressing roller is at least 130°C; the processing time is 1 minute.

[0069] Example 4

[0070] A wood-plastic co-extruded floor comprises a core layer and a surface layer covering the core layer. The raw materials for preparing the surface layer include, by weight: 35% HDPE, 30% PP, 25% elastomer and 10% functional additive.

[0071] The elastomer is selected from one or more of SEBS, SEB, TPU and POE.

[0072] The functional additives at least include antioxidants, light stabilizers, ultraviolet absorbers, lubricants and compatibilizers.

[0073] The functional additives also include mildew inhibitors.

[0074] The raw materials for preparing the core layer include 60% PE, 30% fiber powder, 5% lubricant and 5% processing aid.

[0075] The method for preparing the wood-plastic co-extruded floor comprises the following steps:

[0076] S1, mixing and granulating the core layer material to obtain a core layer granular material;

[0077] S2, mixing and granulating the surface material to obtain the surface granular material;

[0078] S3, co-extruding the core layer granular material in step S1 and the surface layer granular material obtained in step S2 to obtain a coarse co-extruded floor;

[0079] S4, sanding the rough co-extruded floor obtained in step S3 to obtain a fine co-extruded floor;

[0080] S5, hot pressing the fine co-extruded floor, and then placing it for curing to obtain the wood-plastic co-extruded floor.

[0081] In step S5, the hot pressing process is completed by a pair of hot pressing rollers.

[0082] The temperature of the hot pressing roller is at least 120°C; the processing time is 1 minute.

[0083] Example 5

[0084] A wood-plastic co-extruded floor comprises a core layer and a surface layer covering the core layer. The raw materials for preparing the surface layer include, by weight: 35% HDPE, 30% PP, 25% elastomer and 10% functional additive.

[0085] The elastomer is selected from one or more of SEBS, SEB, TPU and POE.

[0086] The functional additives at least include antioxidants, light stabilizers, ultraviolet absorbers, lubricants and compatibilizers.

[0087] The functional additives also include mildew inhibitors.

[0088] The raw materials for preparing the core layer include 60% PE, 30% fiber powder, 5% lubricant and 5% processing aid.

[0089] The method for preparing the wood-plastic co-extruded floor comprises the following steps:

[0090] S1, mixing and granulating the core layer material to obtain a core layer granular material;

[0091] S2, mixing and granulating the surface material to obtain the surface granular material;

[0092] S3, co-extruding the core layer granular material in step S1 and the surface layer granular material obtained in step S2 to obtain a coarse co-extruded floor;

[0093] S4, sanding the rough co-extruded floor obtained in step S3 to obtain a fine co-extruded floor;

[0094] S5, hot pressing the fine co-extruded floor, and then placing it for curing to obtain the wood-plastic co-extruded floor.

[0095] In step S5, the hot pressing process is completed by a pair of hot pressing rollers.

[0096] The temperature of the hot pressing roller is at least 125°C; the processing time is 1 minute.

[0097] Example 6

[0098] A wood-plastic co-extruded floor comprises a core layer and a surface layer covering the core layer. The raw materials for preparing the surface layer include, by weight: 35% HDPE, 30% PP, 25% elastomer and 10% functional additive.

[0099] The elastomer is selected from one or more of SEBS, SEB, TPU and POE.

[0100] The functional additives at least include antioxidants, light stabilizers, ultraviolet absorbers, lubricants and compatibilizers.

[0101] The functional additives also include mildew inhibitors.

[0102] The raw materials for preparing the core layer include 60% PE, 30% fiber powder, 5% lubricant and 5% processing aid.

[0103] The method for preparing the wood-plastic co-extruded floor comprises the following steps:

[0104] S1, mixing and granulating the core layer material to obtain a core layer granular material;

[0105] S2, mixing and granulating the surface material to obtain the surface granular material;

[0106] S3, co-extruding the core layer granular material in step S1 and the surface layer granular material obtained in step S2 to obtain a coarse co-extruded floor;

[0107] S4, sanding the rough co-extruded floor obtained in step S3 to obtain a fine co-extruded floor;

[0108] S5, hot pressing the fine co-extruded floor, and then placing it for curing to obtain the wood-plastic co-extruded floor.

[0109] In step S5, the hot pressing process is completed by a pair of hot pressing rollers.

[0110] The temperature of the hot pressing roller is at least 140°C; the processing time is 1 minute.

[0111] Example 7

[0112] A wood-plastic co-extruded floor comprises a core layer and a surface layer covering the core layer. The raw materials for preparing the surface layer include, by weight: 35% HDPE, 30% PP, 25% elastomer and 10% functional additive.

[0113] The elastomer is selected from one or more of SEBS, SEB, TPU and POE.

[0114] The functional additives at least include antioxidants, light stabilizers, ultraviolet absorbers, lubricants and compatibilizers.

[0115] The functional additives also include mildew inhibitors.

[0116] The raw materials for preparing the core layer include 60% PE, 30% fiber powder, 5% lubricant and 5% processing aid.

[0117] The method for preparing the wood-plastic co-extruded floor comprises the following steps:

[0118] S1, mixing and granulating the core layer material to obtain a core layer granular material;

[0119] S2, mixing and granulating the surface material to obtain the surface granular material;

[0120] S3, co-extruding the core layer granular material in step S1 and the surface layer granular material obtained in step S2 to obtain a coarse co-extruded floor;

[0121] S4, sanding the rough co-extruded floor obtained in step S3 to obtain a fine co-extruded floor;

[0122] S5, hot pressing the fine co-extruded floor, and then placing it for curing to obtain the wood-plastic co-extruded floor.

[0123] In step S5, the hot pressing process is completed by a pair of hot pressing rollers.

[0124] The temperature of the hot pressing roller is at least 150°C; the processing time is 1 minute.

[0125] Comparative Example 1

[0126] The difference between this comparative example and Example 2 is that the raw materials of the surface layer are 55% HDPE, 35% PP and 10% functional additives.

[0127] Comparative Example 2

[0128] The difference between this comparative example and Example 2 is that no hot pressing step is added during the preparation process.

[0129] The inventors conducted the following tests on the wood plastic floor obtained in the above embodiment:

[0130] 1. Floor sanding surface inspection: Take the fine co-extruded floor in step S4 of Examples 1 to 3 and Comparative Examples 1 to 2 and the final product, and check whether there is whitening on the floor surface

[0131]

[0132] Among them, "+" means trace amount, "++" means small amount, "+++" means large amount, and "0" means no amount.

[0133] 2. Impact resistance:

[0134]

[0135] Finally, it should be noted that the above embodiments are only used to illustrate the technical solution of the present invention, rather than to limit the scope of protection of the present invention. Although the present invention has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that the technical solution of the present invention can be modified or replaced by equivalents without departing from the essence and scope of the technical solution of the present invention.

Claims

1. A wood-plastic co-extruded floor, comprising a core layer and a surface layer covering the core layer, characterized in that: The raw materials for preparing the surface layer include, by weight: 30-50% HDPE, 20-40% PP, 20-30% elastomer and 10-15% functional additive; the elastomer is selected from one or more of SEBS, SEB, TPU and POE.

2. A wood-plastic co-extruded floor according to claim 1, characterized in that: The functional additives at least include antioxidants, light stabilizers, ultraviolet absorbers, lubricants and compatibilizers.

3. The wood-plastic co-extruded floor according to claim 2, characterized in that: The functional additives also include mildew inhibitors.

4. The wood-plastic co-extruded floor according to claim 1, characterized in that: The raw materials for preparing the core layer include 40-60% PE, 25-45% fiber powder, 1-5% lubricant and 2-5% processing aid.

5. The method for preparing the wood-plastic co-extruded floor according to any one of claims 1 to 4, comprising the following steps: S1, mixing and granulating the core layer material to obtain a core layer granular material; S2, mixing and granulating the surface material to obtain the surface granular material; S3, co-extruding the core layer granular material in step S1 and the surface layer granular material obtained in step S2 to obtain a coarse co-extruded floor; S4, sanding the rough co-extruded floor obtained in step S3 to obtain a fine co-extruded floor; S5, hot pressing the fine co-extruded floor, and then placing it for curing to obtain the wood-plastic co-extruded floor.

6. The method for preparing a wood-plastic co-extrusion floor according to claim 5, characterized in that: In step S5, the hot pressing process is completed by a pair of hot pressing rollers.

7. The method for preparing a wood-plastic co-extrusion floor according to claim 6, characterized in that: The temperature of the hot pressing roller is at least 120~150℃; the processing time is 1~10min.

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