A modular double-layer composite floor and its manufacturing process

Abstract

This invention discloses an interlocking double-layer composite flooring and its manufacturing process, belonging to the field of composite flooring technology. The interlocking double-layer composite flooring and its manufacturing process include a board body, which comprises an upper layer and a lower layer, with a splicing assembly disposed between the upper and lower layers. This invention solves the problems of existing flooring systems where splicing is difficult, resulting in poor splicing stability, affecting connection effectiveness, poor surface protection, inadequate waterproofing, and poor surface wear resistance. This invention uses a conical column inserted into a conical groove for locking and fixing, improving the stability of the joint after splicing and preventing the flooring from dislodging. A sealing film and a pressing film are pressed together to seal the joint, preventing moisture from entering the board body. The pressing of the film surfaces increases friction, increasing the tightness of the joint and also increasing the stability after assembly. The anti-corrosion layer ensures the overall anti-corrosion performance of the flooring, preventing rotting due to moisture and extending the flooring's service life.

Description

Technical Field

[0001] This invention relates to the field of composite flooring technology, specifically to an assembled double-layer composite floor and its manufacturing process. Background Technology

[0002] Composite flooring is a type of flooring. However, composite flooring involves artificially altering the natural structure of the flooring material to achieve certain physical properties that meet specific requirements. In the market, composite flooring often refers to engineered wood flooring and solid wood composite flooring.

[0003] In the prior art, Chinese Patent Publication No. CN91102806.4 discloses a bamboo-wood composite flooring and its manufacturing process. This patent uses bamboo or wood as the surface and cement, sand, and asphalt as the base materials, which are then bonded together under high temperature and pressure. No adhesive is needed to bond the bamboo or wood materials to the base materials, making the manufacturing process simple. This composite flooring possesses all the advantages of bamboo-wood flooring, but its price is only two-thirds that of traditional bamboo-wood flooring, and it is also easy to install and use.

[0004] The flooring described in the above patent cannot be properly spliced ​​in actual use, resulting in poor splicing stability and affecting the connection effect; secondly, the surface protection effect is poor, it cannot be waterproofed well, and its surface wear resistance is poor. Therefore, it does not meet the current needs. In response, we propose a spliced ​​double-layer composite flooring and its manufacturing process. Summary of the Invention

[0005] The purpose of this invention is to provide an interlocking double-layer composite floor and its manufacturing process. A conical column is inserted into a conical groove for locking and fixing, improving the stability of the joint after splicing and preventing the floor from dislodging. A sealing film and a pressing film are pressed together to seal the joint, preventing moisture from entering the board. The pressing of the film surfaces increases friction, increases the tightness of the joint, and also increases the stability after assembly. Under the action of upper and lower springs, the cushioning effect is improved, giving the floor a slight elasticity, reducing foot noise, and increasing foot comfort. The anti-corrosion layer ensures the overall anti-corrosion performance of the floor, preventing rotting due to moisture and increasing the service life of the floor. This invention solves the problems mentioned in the background art.

[0006] To achieve the above objectives, the present invention provides the following technical solution: a modular double-layer composite floor, comprising a board body, wherein the board body includes an upper layer board and a lower layer board, and a splicing assembly is provided between the upper layer board and the lower layer board;

[0007] The splicing assembly includes left and right splicing components and front and rear splicing components. The left and right splicing components are located on the left and right sides of the panel, and the front and rear splicing components are located at the front and rear ends of the panel. The two panels are spliced ​​and assembled together by the splicing assembly.

[0008] The surface of the plate is covered with protective components.

[0009] Preferably, the left and right splicing components include a locking groove and a pressing strip. The locking groove is opened on the right side of the plate, and the pressing strip is fixed on the left side of the plate. The pressing strip is movably engaged with the locking groove.

[0010] Preferably, the front and rear splicing components include a front connecting groove, a rear connecting block, a locking block, a docking groove, a conical groove, and a conical column. The front connecting groove is opened at the front end of the plate, the rear connecting block is fixed at the rear end of the plate, a locking block is installed in the front connecting groove, a conical groove is opened in the locking block, a docking groove corresponding to the locking block is opened on the rear connecting block, and a conical column is installed in the docking groove.

[0011] Preferably, the locking block and the mating groove are movably inserted, the conical column and the conical groove are movably inserted, and a pressing film is provided on the inner wall of the conical groove, and a sealing film is provided on the outer surface of the conical column. The conical column is sealed and pressed with the conical groove through the sealing film and the pressing film.

[0012] Preferably, the upper and lower plates have built-in slots inside, and a noise reduction structure is installed in the built-in slots. The noise reduction structure includes an upper connecting rod, a lower connecting pipe, an upper connecting spring, and a lower connecting spring. The upper connecting rod is fixed to the upper inner wall of the built-in slot, and the lower connecting pipe is fixed to the bottom wall of the built-in slot. The upper connecting rod is inserted into the lower connecting pipe, and a retaining plate is sleeved at the center of the upper connecting rod. A lower connecting spring is sleeved on the upper connecting rod below the retaining plate.

[0013] Preferably, an upper connecting spring is sleeved on the upper connecting rod above the card plate, and the upper connecting spring and the lower connecting spring are respectively pressed against the upper and lower end faces of the inner wall of the lower connecting pipe;

[0014] The noise reduction structure is provided in multiple ways, and the array of multiple noise reduction structures is installed in the built-in slot.

[0015] Preferably, the protective component includes a decorative layer, a waterproof layer, a protective layer, and an anti-corrosion layer. The decorative layer is coated on the outer surface of the panel, the outer surface of the decorative layer is covered with a waterproof layer, the outer side of the waterproof layer is covered with an anti-corrosion layer, and the outer side of the anti-corrosion layer is covered with a protective layer.

[0016] Preferably, the decorative layer includes a topcoat layer and a primer layer, which are sprayed onto the upper and lower surfaces of the board, respectively. The anti-corrosion layer is composed of film-forming resin, organic corrosion inhibitor, rust inhibitor, organic solvent, castor oil, reactive diluent, aluminum tripolyphosphate, and talc. The protective layer includes a wear-resistant layer and an ultraviolet curing layer. The wear-resistant layer is made of alumina wear-resistant paper, and the ultraviolet curing layer is composed of photoinitiator, resin, filler, additive, heavy metal, and reactive diluent.

[0017] This invention provides another technical solution: a manufacturing process for an assembled double-layer composite floor, comprising the following steps:

[0018] S1: Rotary cutting and drying of boards: After selecting the board material, a core board with a thickness of 1.5 mm is cut by rotary cutting, and then left to dry for a period of time;

[0019] S2: Core board gluing and arranging: The gluing equipment operates on the cut boards to arrange 8-10 layers of glued thin core boards in an orderly, crisscross pattern and bond them together.

[0020] S3: Core board hot press bonding: The boards that are bonded together are sent to the hot press machine, and the boards are bonded together by hot press equipment;

[0021] S4: Substrate surface treatment: The surface and bottom of the floor substrate are sanded with a fixed thickness using a large thickness sander, and the board blank is grooved using a grooving device;

[0022] S5: Paint spraying, drying and shaping: The treated board is sprayed with paint and coated with a waterproof, anti-corrosion and wear-resistant coating. The coating is then dried.

[0023] S6: Floor splicing assembly: Align the front and rear splicing parts on two adjacent front and rear panels and then insert them together. Two adjacent left and right panels are assembled by inserting the left and right splicing parts together.

[0024] Compared with the prior art, the beneficial effects of the present invention are:

[0025] 1. The present invention has a conical column installed in the docking groove, and the locking block and the docking groove are movably inserted. When adjacent plates are spliced, the rear connecting block of the rear end of the plate is aligned and inserted with the front connecting groove of the front end of the other plate. During the insertion, the locking block is inserted into the docking groove, and the conical column is inserted into the conical groove for locking and fixing, which improves the stability of the connection after splicing and prevents the floor from falling off.

[0026] 2. In this invention, the conical column and the conical groove are movably inserted, and a pressing film is provided on the inner wall of the conical groove, while a sealing film is provided on the outer surface of the conical column. The conical column is sealed and pressed with the conical groove through the sealing film and the pressing film. When the conical column and the conical groove are inserted, the sealing film and the pressing film are pressed together to achieve a seal at the connection, preventing moisture from entering the plate. The film surface is pressed together, increasing friction, increasing the tightness of the connection, and also increasing the stability after assembly.

[0027] 3. In this invention, a lower connecting spring is sleeved on the upper connecting rod below the card plate, and an upper connecting spring is sleeved on the upper connecting rod above the card plate. The upper and lower connecting springs are respectively pressed against the upper and lower end faces of the inner wall of the lower connecting pipe. Multiple noise reduction structures are provided, and multiple noise reduction structures are arrayed and installed in the built-in groove. When the floor is in use, when stepping on the floor, the upper part of the floor is subjected to pressure, which drives the upper connecting rod to press down. Under the action of the upper and lower connecting springs, the cushioning effect is improved, making the floor slightly elastic, reducing stepping noise, and also increasing stepping comfort.

[0028] 4. The waterproof layer of this invention is covered with an anti-corrosion layer on the outside, and the anti-corrosion layer is covered with a protective layer on the outside. The decorative layer includes a topcoat layer and a primer layer. The topcoat layer and the primer layer are sprayed on the upper and lower surfaces of the board, respectively. The anti-corrosion layer is composed of film-forming resin, organic corrosion inhibitor, rust inhibitor, organic solvent, castor oil, reactive diluent, aluminum tripolyphosphate and talc. The anti-corrosion layer ensures the anti-corrosion performance of the entire floor, prevents rotting caused by moisture, and improves the service life of the floor. Attached Figure Description

[0029] Figure 1 This is a schematic diagram of the overall structure of the present invention;

[0030] Figure 2 This is a schematic diagram of the left and right splicing components of the present invention;

[0031] Figure 3 This is a schematic diagram of the front and rear splicing components of the present invention;

[0032] Figure 4 For the present invention Figure 1 Enlarged view of point A;

[0033] Figure 5 This is a partial structural diagram of the front and rear splicing components of the present invention;

[0034] Figure 6 This is a partial cross-sectional view of the plate structure of the present invention;

[0035] Figure 7 For the present invention Figure 6 Enlarged view of point C;

[0036] Figure 8 This is a cross-sectional view of the protective component structure of the present invention;

[0037] Figure 9 For the present invention Figure 8 Enlarged view of point B.

[0038] In the diagram: 1. Panel; 11. Upper panel; 12. Lower panel; 13. Internal groove; 2. Splicing assembly; 21. Left and right splicing parts; 211. Locking groove; 212. Pressing strip; 22. Front and rear splicing parts; 221. Front connecting groove; 222. Rear connecting block; 223. Locking block; 224. Butt joint groove; 225. Conical groove; 226. Conical column; 3. Protective assembly; 31. Decorative layer; 32. Waterproof layer; 33. Protective layer; 331. Wear-resistant layer; 332. UV-cured layer; 34. Anti-corrosion layer; 4. Noise reduction structure; 41. Upper connecting rod; 411. Clamping plate; 42. Lower connecting pipe; 43. Upper connecting spring; 44. Lower connecting spring. Detailed Implementation

[0039] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0040] To address the existing issues that prevent proper splicing, leading to poor splicing stability and affecting connection quality, please refer to [link / reference]. Figures 1-7 This embodiment provides the following technical solution:

[0041] A modular double-layer composite floor and its manufacturing process, comprising a board body 1, the board body 1 comprising an upper board 11 and a lower board 12, and a splicing component 2 provided between the upper board 11 and the lower board 12;

[0042] The splicing component 2 includes left and right splicing parts 21 and front and rear splicing parts 22. The left and right splicing parts 21 are disposed on the left and right sides of the panel 1, and the front and rear splicing parts 22 are disposed on the front and rear ends of the panel 1. The two panels 1 are spliced ​​and assembled together by the splicing component 2.

[0043] The left and right splicing parts 21 include a locking groove 211 and a pressing strip 212. The locking groove 211 is opened on the right side of the plate 1, and the pressing strip 212 is fixed on the left side of the plate 1. The pressing strip 212 is movably engaged with the locking groove 211. When splicing two adjacent left and right plates 1, the pressing strip 212 on the left side of the plate 1 is inserted into the locking groove 211 on the right side of the other plate 1 for splicing, effectively performing left and right assembly.

[0044] The front and rear splicing components 22 include a front connecting groove 221, a rear connecting block 222, a locking block 223, a mating groove 224, a tapered groove 225, and a tapered column 226. The front connecting groove 221 is located at the front end of the plate 1, and the rear connecting block 222 is fixed at the rear end of the plate 1. The locking block 223 is installed in the front connecting groove 221, and the tapered groove 225 is provided in the locking block 223. The rear connecting block 222 has a mating groove 224 corresponding to the locking block 223. A tapered column 226 is installed in the groove 224. The locking block 223 and the mating groove 224 are movably inserted. When adjacent panels 1 are spliced, the rear connecting block 222 at the rear end of panel 1 is aligned and inserted with the front connecting groove 221 at the front end of another panel 1. During the insertion, the locking block 223 is inserted into the mating groove 224, and the tapered column 226 is inserted into the tapered groove 225 for locking and fixing, which improves the stability of the connection after splicing and prevents the floor from falling off.

[0045] The conical column 226 is movably inserted into the conical groove 225, and a pressure film is provided on the inner wall of the conical groove 225. A sealing film is provided on the outer surface of the conical column 226. The conical column 226 is sealed and pressed with the conical groove 225 through the sealing film and the pressure film. When the conical column 226 is inserted into the conical groove 225, the sealing film and the pressure film are pressed together to seal the connection, prevent the inside of the plate from getting damp, and the film surface is pressed together to increase friction, increase the tightness of the connection, and also increase the stability after assembly.

[0046] The upper plate 11 and the lower plate 12 have built-in grooves 13 inside. A noise reduction structure 4 is installed within the built-in groove 13. The noise reduction structure 4 includes an upper connecting rod 41, a lower connecting pipe 42, an upper connecting spring 43, and a lower connecting spring 44. The upper connecting rod 41 is fixed to the upper inner wall of the built-in groove 13, and the lower connecting pipe 42 is fixed to the bottom wall of the built-in groove 13. The upper connecting rod 41 is inserted into the lower connecting pipe 42. A retaining plate 411 is sleeved at the center of the upper connecting rod 41. A lower connecting spring 44 is sleeved on the upper connecting rod 41 below the retaining plate 411. An upper connecting spring 43 is sleeved on the upper connecting rod 41 above the board 411. The upper connecting spring 43 and the lower connecting spring 44 are respectively pressed against the upper and lower end faces of the inner wall of the lower connecting pipe 42. Multiple noise reduction structures 4 are provided, and multiple noise reduction structures 4 are arrayed and installed in the built-in groove 13. When the floor is in use, when stepping on the floor, the upper part of the floor is subjected to pressure, which drives the upper connecting rod 41 to press down. Under the action of the upper connecting spring 43 and the lower connecting spring 44, the cushioning effect is improved, the floor has slight elasticity, reduces stepping noise, and also increases stepping comfort.

[0047] To address the issues of poor surface protection, inadequate waterproofing, and poor surface abrasion resistance in existing flooring, please refer to... Figures 8-9 This embodiment provides the following technical solution:

[0048] The surface of the board 1 is covered with a protective component 3, which includes a decorative layer 31, a waterproof layer 32, a protective layer 33, and an anti-corrosion layer 34. The decorative layer 31 is coated on the outer surface of the board 1, and the waterproof layer 32 is covered on the outer surface of the decorative layer 31. The anti-corrosion layer 34 is covered on the outside of the waterproof layer 32, and the protective layer 33 is covered on the outside of the anti-corrosion layer 34. The decorative layer 31 includes a topcoat layer and a primer layer, which are sprayed on the upper and lower surfaces of the board 1, respectively. The anti-corrosion layer 34 is composed of film-forming resin, organic corrosion inhibitor, rust inhibitor, organic solvent, castor oil, reactive diluent, aluminum tripolyphosphate, and talc. The anti-corrosion layer 34 ensures the anti-corrosion performance of the entire floor, prevents rotting caused by moisture, and improves the service life of the floor.

[0049] The protective layer 33 includes a wear-resistant layer 331 and a UV-cured layer 332. The wear-resistant layer 331 is composed of alumina wear-resistant paper. The UV-cured layer 332 is composed of photoinitiator, resin, filler, additives, heavy metals and active diluent. The wear-resistant paper has a high aluminum oxide content per unit area, which makes the entire wear-resistant layer 331 have high wear resistance, improves wear resistance efficiency and increases the protective effect. The UV-cured layer 332 protects the wood floor from wear and corrosion. Some heavy metals are added to the UV coating to improve wear resistance.

[0050] Based on the above-mentioned interlocking double-layer composite flooring, in order to demonstrate the manufacturing process of interlocking double-layer composite flooring, this embodiment proposes a manufacturing process for interlocking double-layer composite flooring, including the following steps:

[0051] S1: Rotary cutting and drying of boards: After selecting the board material, a core board with a thickness of 1.5 mm is cut by rotary cutting, and then left to dry for a period of time;

[0052] S2: Core board gluing and arranging: The gluing equipment operates on the cut boards to arrange 8-10 layers of glued thin core boards in an orderly, crisscross pattern and bond them together.

[0053] S3: Core board hot press bonding: The boards that are bonded together are sent to the hot press machine, and the boards are bonded together by hot press equipment;

[0054] S4: Substrate surface treatment: The surface and bottom of the floor substrate are sanded with a fixed thickness using a large thickness sander, and the board blank is grooved using a grooving device;

[0055] S5: Paint spraying, drying and shaping: The treated board is sprayed with paint and coated with a waterproof, anti-corrosion and wear-resistant coating. The coating is then dried.

[0056] S6: Floor splicing assembly: Align the front and rear splicing parts 22 on two adjacent front and rear panels 1 and then insert them together. Two adjacent left and right panels 1 are assembled by inserting the left and right splicing parts 21 together.

[0057] Working principle: When used on the floor, according to Figure 1 , Figure 2 , Figure 3 , Figure 4 and Figure 5 The rear connecting block 222 at the rear end of plate 1 is aligned and inserted with the front connecting groove 221 at the front end of another plate 1. During insertion, the locking block 223 is inserted into the mating groove 224, and the tapered post 226 is inserted into the tapered groove 225 for locking and fixing. Figure 6 and Figure 7When the floor is in use, the upper part of the floor is subjected to pressure when stepped on, which causes the upper connecting rod 41 to press down. Under the action of the upper connecting spring 43 and the lower connecting spring 44, the cushioning effect is improved, giving the floor a slight elasticity and reducing stepping noise.

[0058] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0059] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A type of modular double-layer composite flooring, comprising a board body (1), characterized in that, The plate (1) includes an upper plate (11) and a lower plate (12). A splicing assembly (2) is provided between the upper plate (11) and the lower plate (12). The splicing assembly (2) includes left and right splicing parts (21) and front and rear splicing parts (22). The left and right splicing parts (21) are located on the left and right sides of the plate (1), and the front and rear splicing parts (22) are located at the front and rear ends of the plate (1). The two plates (1) are spliced ​​and assembled together by the splicing assembly (2). The surface of the plate (1) is covered with a protective component (3). The upper plate (11) and lower plate (12) have internal grooves (13). A noise reduction structure (4) is installed inside the internal groove (13). The noise reduction structure (4) includes an upper connecting rod (41), a lower connecting pipe (42), an upper connecting spring (43), and a lower connecting spring (44). The upper connecting rod (41) is fixed to the upper inner wall of the internal groove (13), and the lower connecting pipe (42) is fixed to the inner wall of the internal groove (13). On the bottom wall, an upper connecting rod (41) is inserted into the lower connecting pipe (42). A retaining plate (411) is sleeved at the center of the upper connecting rod (41). A lower connecting spring (44) is sleeved on the upper connecting rod (41) below the retaining plate (411). An upper connecting spring (43) is sleeved on the upper connecting rod (41) above the retaining plate (411). The upper connecting spring (43) and the lower connecting spring (44) are pressed against the upper and lower end faces of the inner wall of the lower connecting pipe (42), respectively. The noise reduction structure (4) is provided with Multiple noise reduction structures (4) are arranged in an array and installed in the built-in slot (13). The protective component (3) includes a decorative layer (31), a waterproof layer (32), a protective layer (33) and an anti-corrosion layer (34). The decorative layer (31) is coated on the outer surface of the plate (1). The waterproof layer (32) is covered on the outer surface of the decorative layer (31). The anti-corrosion layer (34) is covered on the outside of the waterproof layer (32). The protective layer (33) is covered on the outside of the anti-corrosion layer (34).

2. The modular double-layer composite flooring according to claim 1, characterized in that: The left and right splicing parts (21) include a locking groove (211) and a pressing strip (212). The locking groove (211) is opened on the right side of the plate (1), and the pressing strip (212) is fixed on the left side of the plate (1). The pressing strip (212) is movably locked with the locking groove (211).

3. The modular double-layer composite flooring according to claim 2, characterized in that: The front and rear splicing components (22) include a front connecting groove (221), a rear connecting block (222), a locking block (223), a docking groove (224), a conical groove (225), and a conical column (226). The front connecting groove (221) is opened at the front end of the plate (1), and the rear connecting block (222) is fixed at the rear end of the plate (1). The locking block (223) is installed in the front connecting groove (221), and the conical groove (225) is opened in the locking block (223). The docking groove (224) corresponding to the locking block (223) is opened on the rear connecting block (222), and the conical column (226) is installed in the docking groove (224).

4. The modular double-layer composite flooring according to claim 3, characterized in that: The locking block (223) and the docking groove (224) are movably inserted, the conical column (226) and the conical groove (225) are movably inserted, and a pressing film is provided on the inner wall of the conical groove (225), and a sealing film is provided on the outer surface of the conical column (226). The conical column (226) is sealed and pressed with the conical groove (225) through the sealing film and the pressing film.

5. The modular double-layer composite flooring according to claim 4, characterized in that: The decorative layer (31) includes a topcoat layer and a primer layer, which are sprayed onto the upper and lower surfaces of the board (1) respectively. The anti-corrosion layer (34) is composed of film-forming resin, organic corrosion inhibitor, rust inhibitor, organic solvent, castor oil, reactive diluent, aluminum tripolyphosphate and talc. The protective layer (33) includes a wear-resistant layer (331) and an ultraviolet curing layer (332). The wear-resistant layer (331) is made of wear-resistant paper of aluminum oxide. The ultraviolet curing layer (332) is composed of photoinitiator, resin, filler, additive, heavy metal and reactive diluent.

6. A manufacturing process for the assembled double-layer composite flooring according to claim 5, characterized in that: Includes the following steps: S1: Rotary cutting and drying of boards: After selecting the board material, a core board with a thickness of 1.5 mm is cut by rotary cutting, and then left to dry for a period of time; S2: Core board gluing and arranging: The gluing equipment operates on the cut boards to arrange 8-10 layers of glued thin core boards in an orderly, crisscross pattern and bond them together. S3: Core board hot press bonding: The boards that are bonded together are sent to the hot press machine, and the boards are bonded together by hot press equipment; S4: Substrate surface treatment: The surface and bottom of the floor substrate are sanded with a fixed thickness using a large thickness sander, and the board blank is grooved using a grooving device; S5: Paint spraying, drying and shaping: The treated board is sprayed with paint and coated with a waterproof, anti-corrosion and wear-resistant coating. The coating is then dried. S6: Floor splicing assembly: Align the front and rear splicing parts (22) on two adjacent front and rear panels (1) and then insert them together. The two adjacent left and right panels (1) are assembled by inserting the left and right splicing parts (21).

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