A physical foaming floor

Abstract

The present invention relates to a physical foaming floor, the floor comprises a UV coating, a wear-resistant layer, a color film layer, and a foaming floor substrate layer arranged in sequence, the UV coating is a surface layer, and the raw materials for preparing the foaming floor substrate layer include, by weight: 30-150 parts of PVC resin; 90-120 parts of light calcium carbonate; 1.0-4 parts of carbon nanotubes; 1-3 parts of toughening agent; 1-3 parts of molding agent; 20-40 parts of polystyrene; 50-200 parts of SPC grinding powder recovery material; 8-10 parts of stabilizer; 8-10 parts of plasticizer; 1-2 parts of internal lubricant; 1-2 parts of external lubricant; 0.3-1.0 parts of oxidized polyethylene wax; and 3-10 parts of physical foaming agent. The present invention obtains the foaming floor substrate layer by a physical foaming process, reduces the density of the foaming floor substrate layer, and reduces the cost of raw materials. Compared with the existing SPC floor, the product sound insulation, impact resistance, tensile strength, and static bending strength are improved. The foaming of the foaming floor substrate layer is more uniform than chemical foaming, and there is no odor.

Description

Technical Field

[0001] The invention relates to the technical field of flooring, in particular to a physical foaming flooring. Background Art

[0002] With the continuous development of the PVC flooring industry, it has gradually become a substitute for traditional flooring materials such as solid wood flooring, ceramic tiles, and laminate flooring. Industry experts predict that in the next few years, plastic flooring will be accepted by Chinese people and become a common floor decoration material for home decoration. The rapid development of real estate has put forward a new requirement for the load-bearing of floor materials for high-rise residential and commercial decoration, and also put forward higher requirements for PVC flooring products.

[0003] The traditional SPC floor has a high density, which causes the weight per unit area to increase during the decoration process and also increases transportation costs. Summary of the invention

[0004] Based on this, it is necessary to provide a physical foaming floor with low density.

[0005] To achieve the above object, the present invention provides a technical solution:

[0006] A physical foam floor, the floor comprises a UV coating, a wear-resistant layer, a color film layer, and a foam floor substrate layer arranged in sequence, the UV coating is a surface layer, and the raw materials for preparing the foam floor substrate layer include, by weight:

[0007]

[0008]

[0009] Preferably, the physical blowing agent includes at least one of carbon dioxide, nitrogen, butane and pentane.

[0010] The toughening agent includes at least one of hydrogenated styrene-butadiene block copolymer, polyurethane and maleic anhydride grafted ethylene octene copolymer.

[0011] The molding agent includes chlorinated polyethylene (CPE).

[0012] In parts by weight, the PVC resin includes 50-90 parts of PVC resin SG5 and 30-60 parts of PVC resin SG8.

[0013] Specifically, the mesh size of light calcium carbonate is 500-1000 meshes. Calcium carbonate plays a filling role and can effectively improve the hardness and stability of the material.

[0014] The influence of carbon nanotubes (CNTs) content on the surface density, mechanical properties, sound insulation and thermal insulation properties of PVC foam materials. PVC foam materials with CNTs have better comprehensive properties. Compared with PVC foam materials without adding CNTs, the tensile strength is improved, the elastic modulus is improved, the impact strength is improved, and the sound insulation index is improved.

[0015] At the same time, the foaming efficiency of SPC milled recycled materials is low, and the addition of CNTs improves the foaming performance.

[0016] The outer diameter of the carbon nanotube is 0.6nm to 80nm. , preferably 2nm to 20nm;

[0017] The carbon content of the carbon nanotubes is 80-100wt%, preferably 90-100wt%. The carbon nanotubes are evenly distributed in the foamed substrate, which reduces the porosity of the foamed substrate and enhances the density of the material. At the same time, due to their inert chemical characteristics, the carbon nanotubes are extremely stable and almost do not react with acids, alkalis and salts. Therefore, they can better protect the substrate and prevent deep corrosion, thereby improving the corrosion resistance of the material as a whole.

[0018] The addition of polystyrene ensures that the raw materials do not decompose or become sticky during the foaming process, makes the polar polyvinyl chloride and non-polar polystyrene well compatible, and makes the foaming ratio easy to control.

[0019] Adding recyclable SPC grinding powder can reduce costs.

[0020] Plasticizers promote the plasticization of PVC, improve the melt strength of PVC, prevent bubbles from merging or bursting, ensure that the melt has good fluidity, and improve the surface gloss of the product.

[0021] The internal lubricant is specifically one or more of stearic acid or modified stearic acid; its main function is to lubricate the contact surface of the composite material, making it have better fluidity, thereby preventing the workpiece from being scratched.

[0022] The external lubricant is polyethylene wax, which improves the fluidity between the material and the equipment barrel and the mold, reduces the friction between the material and the equipment, and improves the plasticization effect of the material.

[0023] Oxidized polyethylene wax (OPE) does not decompose at higher temperatures, improves the lubricity between materials and equipment, reduces the friction between materials and extrusion screws, and increases the service life of the screws.

[0024] Preferably, the steps of preparing the foam floor substrate layer include:

[0025] Light calcium carbonate, carbon nanotubes and PVC resin are added to a high-speed mixer for stirring, and then toughening agent, stabilizer, plasticizer, internal lubricant, external lubricant, oxidized polyethylene wax, molding agent and SPC milled powder recovery material are added for stirring and mixing, and when the stirring temperature rises to 120° C., stirring is stopped and the material is discharged to obtain a first mixed material;

[0026] Cooling the first mixed material to 75° C., feeding the cooled first mixed material into a twin-screw extruder for extrusion processing, subjecting the physical foaming agent to high-pressure liquefaction treatment in the extrusion barrel of the twin-screw extruder, mixing the high-pressure liquefied physical foaming agent with the first mixed material in an extrusion and melting section to obtain a second mixed material, and during the extrusion process of the second mixed material, releasing the pressure of the extrusion barrel;

[0027] The second mixed material after extrusion is subjected to foaming molding treatment to obtain a foamed floor substrate layer.

[0028] Preferably, the thickness of the foam floor substrate layer is 4.2 mm to 7 mm.

[0029] Preferably, the stabilizer includes at least one of an environmentally friendly rare earth stabilizer and a composite stabilizer.

[0030] Preferably, the plasticizer includes at least one of acrylate and chlorinated polyethylene.

[0031] Preferably, the mass ratio of the internal lubricant to the external lubricant is 1:(1-1.2).

[0032] Preferably, the SPC ground powder recycling material includes SPC scraps and slotted ash ground powder.

[0033] Beneficial effects of the present invention:

[0034] The present invention uses a physical foaming process to prepare a foam floor substrate layer, which reduces the density of the foam floor substrate layer and reduces the cost of raw materials. Compared with the existing SPC floor, the product has improved sound insulation, impact resistance, tensile strength, and static bending strength. The foaming of the foam floor substrate layer is more uniform than chemical foaming and has no odor. DETAILED DESCRIPTION

[0035] In order to better illustrate the purpose, technical solutions and advantages of the present invention, the present invention will be further described below in conjunction with specific embodiments.

[0036] In the examples, the test methods used are conventional methods unless otherwise specified, and the materials, reagents, etc. used are all commercially available unless otherwise specified.

[0037] The distribution ratios of each group of plasticizer examples 1 to 4 and comparative examples 1 to 3 are as follows: Table 1

[0038] Table 1 Distribution ratio of each group

[0039]

[0040] The sheet extrusion process is as follows:

[0041] Step A:

[0042] Light calcium carbonate, CNTs and PVC resin are added to a high-speed mixer and stirred. The heat for heating comes from the mixer itself. After mixing and stirring, toughening agent, stabilizer, plasticizer, internal lubricant, external lubricant, oxidized polyethylene wax, molding agent, SPC milled powder recycling material are added and stirred and mixed. When the temperature reaches 120°C, the material is discharged to obtain the first mixed material. (During high-speed mixing, due to the high shear force generated by heat, mutual collision and friction, the material temperature continues to rise, the PVC particles and other components continue to penetrate each other, and the surface of the PVC resin particles gradually absorbs or adsorbs the stabilizer, the melted lubricant, and the processing plasticizer)

[0043] Step B:

[0044] The first mixed material is cooled to 75°C, and the cooled first mixed material is fed into the storage bin of the twin-screw extruder, and the mixed material is fed into the twin-screw extruder for extrusion processing through the automatic feeding system. The 5-section temperature control of the barrel is 190°C, 190°C, 185°C, 180°C, and 175°C from front to back respectively, and the screw enters the mold. The seven-section temperature control of the mold is 220°C, 220°C, 210°C, 210°C, 201°C, 230°C, and 230°C respectively. The material is extruded through the die mouth to extrude the substrate. (In terms of extrusion technology, the basic principle of temperature setting is: the temperature of each barrel zone of the extruder is set from high to low, and the temperature of zones 1 and 2 should be higher to promote plasticization.

[0045] Step C:

[0046] In the extrusion and integration stage, the fourth stage of high-pressure liquefied physical foaming agent in the extrusion barrel is subjected to high-pressure liquefaction treatment, and the high-pressure liquefied physical foaming agent is mixed with the first mixed material in the extrusion and integration stage to obtain the second mixed material. The high-pressure liquefied foaming agent maintains the high pressure in the mold cavity so that it continues to exist in a liquid state and is fully mixed with the first mixed material. During the extrusion process, the pressure is released to form fine micropores. The pressure is 10 MPa, the temperature is 175°C, and the time is 20 seconds.

[0047] Step D:

[0048] The foam floor substrate layer is obtained through step C, and the UV coating, the wear-resistant layer, the color film layer and the foam floor substrate layer are introduced into a five-roll laminating device, and the thickness is determined by the gap between the first roller and the second roller; the surface layer is laminated on the third roller; the fifth roller is calendered; the temperature of the first, second and third calendering rollers is 190°C, and the temperature of the fourth and fifth calendering rollers is 90°C; the calendering speed is 1.5m / min; the calendering speed ratio is 1:1.3; after calendering, the material is unloaded through a lifting machine, and the unloading temperature is 40°C; plasticization and calendering are performed to form a foam floor substrate layer of a certain thickness.

[0049] The test results of Examples 1 to 3 and Comparative Examples 1 to 2 are shown in Table 2.

[0050] Table 2 Test results

[0051]

[0052] As shown in Table 2, the density of conventional non-foamed substrates is 2.0 g / cm 3 Reduced to 1.6g / cm 3 ; Shrinkage (%) is all below 0.1; impact resistance, sound insulation and static bending strength are also greatly improved.

[0053] It should be noted that the specific parameters or some reagents in the above embodiments are specific embodiments or preferred embodiments of the present invention, rather than limiting the present invention; those skilled in the art can make adaptive adjustments within the scope of the present invention.

Claims

1. A physical foaming floor, characterized in that: The floor comprises a UV coating, a wear-resistant layer, a color film layer, and a foam floor substrate layer arranged in sequence, wherein the UV coating is a surface layer, and the raw materials for preparing the foam floor substrate layer include, by weight: The physical foaming agent includes at least one of carbon dioxide, nitrogen, butane and pentane.

2. The floor according to claim 1, characterized in that The steps of preparing the foamed floor substrate layer include: Light calcium carbonate, carbon nanotubes and PVC resin are added to a high-speed mixer and stirred, and then toughening agent, stabilizer, plasticizer, internal lubricant, external lubricant, oxidized polyethylene wax, molding agent and SPC milled powder recovery material are added and stirred and mixed, and when the stirring temperature rises to 110-120° C., stirring is stopped and the material is discharged to obtain a first mixed material; Cooling the first mixed material to 65-75° C., feeding the cooled first mixed material into a twin-screw extruder for extrusion processing, subjecting the physical foaming agent to high-pressure liquefaction treatment in the extrusion sealing barrel of the twin-screw extruder, mixing the high-pressure liquefied physical foaming agent with the first mixed material in the extrusion and melting section to obtain a second mixed material, and during the extrusion process of the second mixed material, releasing the pressure on the mold connected to the end of the extrusion barrel; The second mixed material after extrusion is subjected to foaming molding treatment to obtain a foamed floor substrate layer.

3. The floor panel according to claim 1, characterized in that: The thickness of the foam floor substrate layer is 4.2 mm to 7 mm.

4. The floor panel according to claim 1, characterized in that: The outer diameter of the carbon nanotube is 0.6nm-80nm.

5. The floor panel according to claim 1, characterized in that: The plasticizer includes at least one of acrylate and chlorinated polyethylene.

6. The floor panel according to claim 1, characterized in that The mass ratio of the internal lubricant to the external lubricant is 1:(1-1.2).

7. The floor panel according to claim 1, characterized in that: The SPC powder recycling material includes SPC scraps and slotted ash powder.

8. The floor panel according to claim 7, characterized in that The recycling process of the SPC milling recycled material comprises: The large-plate SPC substrate is crushed to obtain a crushed small-plate substrate; The crushed small plate substrate is ground and dried by a grinding machine at a drying temperature of 70 to 90 degrees to obtain the SPC ground recycled material.

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