Modified melamine impregnated flooring and process for its production

Abstract

The application discloses a modified melamine impregnated decorative floor and a production process thereof, and belongs to the technical field of floors. The modified melamine impregnated decorative floor comprises, from top to bottom, a modified melamine resin glue impregnated decorative layer, a modified PVC base material and modified melamine resin glue impregnated balance paper. The modified melamine resin glue is prepared by the following steps: 120g of melamine, 8-10g of glyoxal, 6-8g of urea and 15-20mL of a 10% polyvinyl alcohol solution are added into a reaction container, ultrasonic dispersion is carried out for 5-10min, the pH is adjusted to 5-6, stirring and temperature rising are carried out until 65 DEG C, reaction is carried out for 70min, and cooling is carried out, so that the modified melamine resin glue is obtained. The modified melamine resin glue and the modified PVC base material can effectively prevent the melamine impregnated decorative floor from problems such as bulging and deformation, and upward warping around the floor in a humid environment.

Description

TECHNICAL FIELD

[0001] The application belongs to the technical field of floor, and particularly relates to a modified melamine impregnated decorative floor and a production process thereof. BACKGROUND

[0002] The melamine impregnated decorative floor uses PVC as a base material, does not depend on large-diameter logs, and is beneficial to environmental protection. The surface hardness and wear resistance are high, and the floor is easy to maintain. However, the PVC is a thermoplastic resin composite material, and the melamine impregnated paper and the PVC are combined through a hot pressing process. The following three problems exist: 1. continuous exposure to a humid environment, such as a kitchen, a bathroom, a laundry room and a basement area of a house, will cause the floor to swell and deform; 2. the shrinkage and expansion rates are large due to the influence of environmental temperature and humidity; and 3. the environmental humidity has a large influence, and the floor is prone to upward warping around the periphery. SUMMARY

[0003] The application aims to provide a modified melamine impregnated decorative floor and a production process thereof, so as to solve the following technical problems: 1. continuous exposure to a humid environment, such as a kitchen, a bathroom, a laundry room and a basement area of a house, will cause the floor to swell and deform; 2. the shrinkage and expansion rates are large due to the influence of environmental temperature and humidity; and 3. the environmental humidity has a large influence, and the floor is prone to upward warping around the periphery.

[0004] The object of the application can be achieved by the following technical solutions.

[0005] A modified melamine impregnated decorative floor comprises, from top to bottom, a modified melamine resin glue impregnated decorative layer, a modified PVC base material and a modified melamine resin glue impregnated balancing paper.

[0006] The modified melamine resin glue is prepared by the following steps:

[0007] 120g of melamine, 8-10g of glyoxal, 6-8g of urea and 15-20mL of a polyvinyl alcohol solution with a mass fraction of 10% are added to a reaction container, ultrasonic dispersion is performed for 5-10min, the pH is adjusted to 5-6, stirring is performed to warm up to 65℃, reaction is performed for 70min, and cooling is performed to obtain the modified melamine resin glue.

[0008] The polyvinyl alcohol solution itself has good adhesion, reacts with the hydroxyl groups in the resin to form a crosslinked structure, so that the resin glue system contains a large amount of ring structures, the existence of the ring structures improves the initial adhesion of the resin glue, and the adhesion strength of the decorative layer, the balancing paper and the PVC base material is improved.

[0009] As a further scheme of the application, the modified PVC base material is prepared by the following steps:

[0010] According to the application, 100 parts of PVC resin, 10-15 parts of light calcium carbonate, 7-10 parts of calcium stearate, 55-65 parts of short glass fiber, 5-10 parts of silane coupling agent and 8-20 parts of oxidized polyethylene wax are stirred at 100-110 DEG C for 3-8 min, and then cooled to 35-40 DEG C, and then conveyed to an extruder for extrusion to obtain the modified PVC base material. The short glass fiber has high density, and can enhance the compactness of the PVC base material and improve the water resistance of the PVC base material. The silane coupling agent can enhance the compatibility of the PVC resin with the short glass fiber, light calcium carbonate and calcium stearate. The silane group in the silane coupling agent is attached to the surface of the PVC base material as a hydrophobic functional group to form a hydrophobic film, so that the water resistance of the PVC base material is further improved.

[0011] As a further scheme of the application, the solvent of the polyvinyl alcohol solution is glycerol. The addition of glycerol enables the hydrogen bond to be formed between the polyvinyl alcohol molecular chain and the alcohol hydroxyl group, so that the original hydrogen bond in the polyvinyl alcohol molecule is replaced by a new hydrogen bond, the stability of the hydroxyl group in the polyvinyl alcohol molecular chain is improved, and the thermal stability of the resin glue is improved.

[0012] As a further scheme of the application, the production process of the modified melamine impregnated decorative floor comprises the following steps:

[0013] Step S1, preparation of the modified melamine resin glue impregnated decorative layer: the material of the decorative layer is impregnated with the modified melamine resin glue and dried, and the impregnation amount of the material of the dried decorative layer is controlled to be 140%-150%;

[0014] Step S2, preparation of the modified melamine resin glue impregnated balance paper: the balance base paper is impregnated with the modified melamine resin glue and dried, and the impregnation amount of the dried balance paper is controlled to be 140%-160%;

[0015] Step S3, floor processing: the modified PVC base material is combined on the modified melamine resin glue impregnated balance paper prepared in step S2, and the modified melamine resin glue impregnated decorative layer prepared in step S1 is laid on the modified PVC base material, and then sent into a hot press for molding, cutting, curing, balancing and slotting to obtain a modified melamine impregnated decorative floor.

[0016] As a further scheme of the application, the material of the decorative layer is any one of the combination of wear-resistant base paper and decorative base paper and wear-resistant decorative base paper.

[0017] The application has the following beneficial effects:

[0018] The application modifies melamine resin glue by adding polyvinyl alcohol solution to the raw material for preparing melamine resin glue, the polyvinyl alcohol solution itself has good adhesion, reacts with the hydroxyl group in the resin to form a crosslinked structure, so that the resin glue system contains a large amount of ring structure, the presence of the ring structure improves the initial adhesion of the resin glue, which is beneficial to improve the adhesion strength of the decorative layer, the balance paper and the PVC substrate; and glycerol is selected as the solvent of the polyvinyl alcohol solution, the addition of glycerol, the embedding of the polyvinyl alcohol molecular chain and the alcohol hydroxyl group forms a hydrogen bond, so that the original hydrogen bond in the polyvinyl alcohol molecule is replaced by a new hydrogen bond, the stability of the hydroxyl group of the polyvinyl alcohol molecular chain is improved, the thermal stability of the resin glue is improved, and the thermal stability of the modified melamine resin glue impregnated decorative layer and the modified melamine resin glue impregnated balance paper is improved, and the shrinkage and expansion rate is reduced.

[0019] The application modifies the PVC substrate by adding short glass fibers and silane coupling agent to the raw material for preparing the PVC substrate, the short glass fibers have high density, which enhances the compactness of the PVC substrate and improves the water resistance of the PVC substrate; the silane coupling agent enhances the compatibility of the PVC resin, the short glass fibers, the light calcium carbonate and the calcium stearate; the silane group in the silane coupling agent is attached to the surface of the PVC substrate as a hydrophobic functional group, forming a hydrophobic film, thereby further improving the water resistance of the PVC substrate.

[0020] In summary, the application improves the thermal stability of the modified melamine resin glue impregnated decorative layer and the modified melamine resin glue impregnated balance paper, the adhesion strength of the PVC substrate and the water resistance of the PVC substrate, and reduces the shrinkage and expansion rate of the decorative layer and the balance paper, thereby effectively preventing the melamine impregnated decorative floor from swelling and deforming, and the surrounding upward warping problem in a humid environment. DETAILED DESCRIPTION

[0021] The technical solutions in the embodiments of the application will be clearly and completely described below with reference to the embodiments of the application. Obviously, the described embodiments are only a part of the embodiments of the application, rather than all the embodiments of the application. Based on the embodiments in the application, all other embodiments obtained by those skilled in the art without creative labor fall within the scope of protection of the application.

[0022] Embodiment 1

[0023] The modified melamine resin glue is prepared by the following steps:

[0024] 120g of melamine, 8g of glyoxal, 6g of urea, and 15mL of a 10% polyvinyl alcohol solution (solvent: glycerol) were added to a reaction vessel. The mixture was ultrasonically dispersed for 5 minutes, the pH was adjusted to 5, and the mixture was stirred and heated to 65°C. The reaction was carried out for 70 minutes and then cooled to obtain modified melamine resin adhesive.

[0025] Example 2

[0026] The modified melamine resin adhesive is prepared by the following steps:

[0027] Add 120g melamine, 10g glyoxal, 8g urea, and 20mL of a 10% polyvinyl alcohol solution (solvent is glycerol) to a reaction vessel, sonicate for 10min, adjust the pH to 6, stir and heat to 65℃, react for 70min, cool, and obtain modified melamine resin glue.

[0028] Example 3

[0029] The modified PVC substrate is prepared by the following steps:

[0030] By weight, 100 parts of PVC resin, 10 parts of light calcium carbonate, 7 parts of calcium stearate, 55 parts of short glass fiber, 5 parts of silane coupling agent, and 8 parts of oxidized polyethylene wax are stirred at 100°C for 3 minutes, then cooled to 35°C and fed to an extruder for extrusion to obtain modified PVC substrate.

[0031] Example 4

[0032] The modified PVC substrate is prepared by the following steps:

[0033] By weight, 100 parts of PVC resin, 15 parts of light calcium carbonate, 10 parts of calcium stearate, 65 parts of short glass fiber, 10 parts of silane coupling agent, and 20 parts of oxidized polyethylene wax are stirred at 110°C for 8 minutes, then cooled to 40°C and extruded through an extruder to obtain a modified PVC substrate.

[0034] Example 5

[0035] A production process for modified melamine-impregnated decorative flooring includes the following steps:

[0036] Step S1: Preparation of modified melamine resin impregnation decorative layer: Impregnate the wear-resistant decorative base paper with the modified melamine resin prepared in Example 1 and dry it. The impregnation amount of the dried wear-resistant decorative base paper is controlled at 140%-150%.

[0037] Step S2: Preparation of balancing paper impregnated with modified melamine resin: The balancing base paper is impregnated with the modified melamine resin prepared in Example 1 and dried. The impregnation amount of the dried balancing paper is controlled at 140%-160%.

[0038] Step S3, floor processing: the modified PVC substrate prepared in Example 3 is combined on the modified melamine resin impregnated balancing paper prepared in step S2, and the modified melamine resin impregnated decorative layer prepared in step S1 is laid on the modified PVC substrate, and then sent into a hot press for molding, and then cut, balanced, grooved and tenoned to obtain a modified melamine impregnated decorative floor.

[0039] Example 6

[0040] A production process of a modified melamine impregnated decorative floor, comprising the following steps:

[0041] Step S1, preparation of a modified melamine resin impregnated decorative layer: the wear-resistant decorative base paper is impregnated with the modified melamine resin glue prepared in Example 2, and dried, and the impregnation amount of the dried wear-resistant decorative base paper is controlled to be 140%-150%;

[0042] Step S2, preparation of a modified melamine resin impregnated balancing paper: the balancing base paper is impregnated with the modified melamine resin glue prepared in Example 2, and dried, and the impregnation amount of the dried balancing paper is controlled to be 140%-160%;

[0043] Step S3, floor processing: the modified PVC substrate prepared in Example 4 is combined on the modified melamine resin impregnated balancing paper prepared in step S2, and the modified melamine resin impregnated decorative layer prepared in step S1 is laid on the modified PVC substrate, and then sent into a hot press for molding, and then cut, balanced, grooved and tenoned to obtain a modified melamine impregnated decorative floor.

[0044] Example 7

[0045] A production process of a modified melamine impregnated decorative floor, comprising the following steps:

[0046] Step S1, preparation of a modified melamine resin impregnated decorative layer: the wear-resistant decorative base paper is impregnated with the modified melamine resin glue prepared in Example 1, and dried, and the impregnation amount of the dried wear-resistant decorative base paper is controlled to be 140%-150%;

[0047] Step S2, preparation of a modified melamine resin impregnated balancing paper: the balancing base paper is impregnated with the modified melamine resin glue prepared in Example 1, and dried, and the impregnation amount of the dried balancing paper is controlled to be 140%-160%;

[0048] Step S3, floor processing: the modified PVC substrate prepared in Example 4 was combined on the modified melamine resin impregnated balance paper prepared in Step S2, and the modified melamine resin impregnated decorative layer prepared in Step S1 was laid on the modified PVC substrate, and then sent into a hot press for molding, and then cut, balanced, grooved and tenoned to obtain a modified melamine impregnated decorative floor.

[0049] Comparative Example 1

[0050] The modified melamine resin glue was prepared by the following steps:

[0051] The present comparative example was compared with Example 1, only the "solvent glycerol of polyvinyl alcohol solution was replaced by water", and the rest of the steps and parameters were the same.

[0052] Comparative Example 2

[0053] The modified melamine resin glue was prepared by the following steps:

[0054] The present comparative example was compared with Example 1, without adding "15 mL of 10% polyvinyl alcohol solution (solvent is glycerol)", and the rest of the steps and parameters were the same.

[0055] Comparative Example 3

[0056] The modified PVC substrate was prepared by the following steps:

[0057] The present comparative example was compared with Example 3, without adding "55 parts of short glass fiber, 5 parts of silane coupling agent", and the rest of the steps and parameters were the same.

[0058] Comparative Example 4

[0059] A production process of a modified melamine impregnated decorative floor, comprising the following steps:

[0060] The present comparative example was compared with Example 5, replacing "the modified melamine resin glue prepared in Example 1" with "the modified melamine resin glue prepared in Comparative Example 1", and replacing "the modified PVC substrate prepared in Example 3" with "the modified PVC substrate prepared in Comparative Example 3", and the rest of the steps and parameters were the same.

[0061] Comparative Example 5

[0062] A production process of a modified melamine impregnated decorative floor, comprising the following steps:

[0063] The present comparative example was compared with Example 5, replacing "the modified melamine resin glue prepared in Example 1" with "the modified melamine resin glue prepared in Comparative Example 2", and replacing "the modified PVC substrate prepared in Example 3" with "the modified PVC substrate prepared in Comparative Example 3", and the rest of the steps and parameters were the same.

[0064] The following performance tests were conducted on a modified melamine impregnated decorative floor produced according to Examples 5-7 and a modified melamine impregnated decorative floor produced according to Comparative Examples 4-5:

[0065] (1) Bonding strength: the test floor was cut into a length of l = 100 mm, a width of b = 25 mm and immersed in a constant temperature water bath at 60-65°C for 3 h, then removed, cooled and dried. The two ends of the test floor were clamped in a pair of movable clamps of a testing machine, with the center of the test floor passing through the axis of the movable clamps of the testing machine. The test floor was subjected to a constant speed load until it was destroyed, with a loading speed of 10 MPa / min. The maximum destructive load (N) was recorded, and the bonding strength was calculated according to the following formula:

[0066] Bonding strength (MPa) = maximum destructive load (N) / (b*l)

[0067] (2) Water absorption thickness expansion rate / %, dimensional stability (dimensional change / mm) were tested according to GB / T 18102-2007;

[0068] (3) Surface resistance to cold and hot cycle test was conducted according to GB / T 17657-1999 (4.31), and whether the test floor surface had bubbles and other conditions was recorded;

[0069] The above test results are shown in Table 1:

[0070] Table 1

[0071]

[0072]

[0073] As can be seen from Table 1, the modified melamine impregnated decorative floor produced according to Examples 5-7 has stronger bonding strength of the decorative layer, the balancing paper and the PVC substrate, and is less affected by environmental temperature and humidity, compared to the modified melamine impregnated decorative floor produced according to Comparative Examples 4-5.

[0074] The thermal stability of the modified melamine resin glue impregnated decorative layer, the modified melamine resin glue impregnated balancing paper, the bonding strength of the PVC substrate and the water resistance of the PVC substrate, and the reduction of the shrinkage and expansion rate of the decorative layer and the balancing paper,

[0075] It is to be understood that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting; it is not intended to exclude myriad other embodiments of the present application that other inventors can develop based on the same general inventive concepts embodied by the described embodiments. That is, although the present application is described in terms of particular embodiments and illustrative figures, it should be apparent that the scope of the present application is not limited to these specific embodiments.

[0076] While the embodiments of the application have been shown and described herein, it will be understood by those skilled in the art that many changes, modifications, substitutions and alterations to these embodiments can be made without departing from the principles and spirits of the application, and it is intended that the scope of the application be limited solely by the scope of the appended claims and the equivalents thereof.

Claims

1. A modified melamine-impregnated decorative flooring, characterized in that, It includes, from top to bottom, a modified melamine resin impregnated decorative layer, a modified PVC substrate, and a modified melamine resin impregnated balance paper; The modified melamine resin adhesive is prepared by the following steps: Add 120g melamine, 8-10g glyoxal, 6-8g urea, and 15-20mL of 10% polyvinyl alcohol solution to a reaction vessel, sonicate for 5-10min, adjust pH to 5-6, stir and heat to 65℃, react for 70min, cool, and obtain modified melamine resin glue. The modified PVC substrate is prepared by the following steps: By weight, 100 parts of PVC resin, 10-15 parts of light calcium carbonate, 7-10 parts of calcium stearate, 55-65 parts of short glass fiber, 5-10 parts of silane coupling agent, and 8-20 parts of oxidized polyethylene wax are stirred at 100-110℃ for 3-8 minutes, then cooled to 35-40℃ and fed to an extruder for extrusion to obtain modified PVC substrate. The solvent for the polyvinyl alcohol solution is glycerol.

2. The production process of a modified melamine-impregnated decorative flooring according to claim 1, characterized in that, Includes the following steps: Step S1: Preparation of the decorative layer impregnated with modified melamine resin: The material of the decorative layer is impregnated with modified melamine resin and dried. The impregnation amount of the material of the dried decorative layer is controlled at 140%-150%. Step S2, Preparation of balancing paper impregnated with modified melamine resin: The balancing base paper is impregnated with modified melamine resin and dried. The impregnation amount of the dried balancing paper is controlled at 140%-160%. Step S3, Flooring Processing: The modified PVC substrate is combined with the modified melamine resin impregnation balance paper obtained in step S2, and then the modified melamine resin impregnation decorative layer obtained in step S1 is laid on the modified PVC substrate. It is then sent into a hot press for molding, and after slitting, curing and balancing, and grooving, a modified melamine impregnation decorative flooring is obtained.

3. The production process of a modified melamine-impregnated decorative flooring according to claim 2, characterized in that, The material of the decorative layer is a combination of wear-resistant base paper and decorative base paper, or any one of wear-resistant and decorative base paper.

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