Lightweight moulded SPC panel and process for its production

Abstract

The application discloses a kind of light mould pressing SPC board and production process thereof, belong to plate technical field.Utilize opening mould pressing forming method to prevent layer, film layer, substrate layer and bottom layer are tightly combined to form SPC board.Prevent layer in polyurethane acrylate and acrylate monomer by silicon oil hydrophobic modification, unlike traditional UV layer material, with excellent hydrophobic property, and while adding modified nano silicon dioxide to improve the wear resistance of protective layer.Substrate layer is composed of two different materials, TPU and stainless steel fiber are composed of core layer, calcium carbonate, polyvinyl chloride and other additives are composed of shell layer, reduce the proportion of high-density calcium carbonate in plate while ensuring the temperature resistance of plate, and the light SPC board is obtained by multilayer structure pressing.

Description

Technical Field

[0001] This invention belongs to the field of sheet technology, specifically relating to a lightweight molded SPC sheet and its production process. Background Technology

[0002] SPC sheets are composite sheets made from stone powder and thermoplastic polymers, which are mixed evenly and then extruded at high temperatures. They combine the properties and characteristics of both wood and plastic, ensuring both strength and toughness. Traditional SPC sheets are made from 25% polyvinyl chloride and 75% lime powder, typically consisting of four layers: a UV layer, a wear-resistant layer, a printed color film layer, and a substrate layer. During processing, the wear-resistant layer, UV layer, and color film layer are sequentially heated and pressed onto the substrate layer using a three-roll or four-roll calender. Compared to calendering, compression molding has irreplaceable advantages, allowing for the production of thicker sheets. Lamination molding, specifically an open-face compression molding method, is an older and more mature process characterized by high-quality products and a stable and simple process, making it suitable for sheet processing.

[0003] In summary, SPC sheets are formaldehyde-free, environmentally friendly, safe, waterproof, and wear-resistant. However, in practical applications, their high density and weight make them unsuitable for transportation. They may also experience shrinkage or expansion due to temperature changes. These phenomena can lead to problems such as cracking, bulging, and deformation.

[0004] Patent application CN202211264472.9 discloses a micro-foaming technology SPC lightweight flooring, which reduces the specific gravity of the flooring by adding a micro-foaming agent to the substrate. However, the formation of a porous structure in the substrate will affect the strength of the board, requiring the addition of anti-toughness and anti-impact additives. There are also potential risks related to the compatibility between materials. Summary of the Invention

[0005] The purpose of this invention is to provide a lightweight molded SPC sheet and its production process, thereby reducing the weight of the SPC sheet.

[0006] The objective of this invention can be achieved through the following technical solutions:

[0007] This invention provides a lightweight molded SPC sheet, which, from top to bottom, comprises a protective layer, a color film layer, a substrate layer, and a bottom layer;

[0008] The substrate layer includes a core layer and a shell layer.

[0009] The core layer material comprises, by weight, 90-98 parts of thermoplastic polyurethane resin and 2-10 parts of stainless steel fiber;

[0010] The shell material comprises, by weight parts: 65-80 parts calcium carbonate, 20-35 parts polyvinyl chloride resin, 2-5 parts calcium zinc stabilizer, 1-3 parts titanate coupling agent, and 1-2 parts stearic acid.

[0011] Furthermore, the protective layer raw materials, by weight, include: 70-90 parts of modified polyurethane acrylate, 10-30 parts of modified trimethylolpropane triacrylate, 1-5 parts of modified nano silica, 0.1-0.3 parts of leveling agent, 0.1-0.5 parts of defoamer, and 0.5-1 parts of photoinitiator.

[0012] Furthermore, the modified polyurethane acrylate is prepared as follows:

[0013] S1. Isophorone diisocyanate and ethyl acetate were added to the reaction vessel at a mass ratio of 2:5, and 0.1% of 4-methoxyphenol and 0.2% of dibutyltin dilaurate were added. The mixture was stirred and heated to 40°C.

[0014] S2. Triethylene glycol with a molar ratio of 1:2 to isophorone diisocyanate was added dropwise at 40℃, and the reaction was carried out for 2 hours after the addition was completed.

[0015] S3. Heat to 60℃ and add dropwise IOTA-8865H, a long-chain alkyl silicone oil with a dihydroxyl end of diisocyanate in a molar ratio of 1:4 to isophorone diisocyanate. After the addition is complete, heat to 110℃ and react for 2 hours.

[0016] S4. After cooling to 80℃, hydroxyethyl acrylate with a molar ratio of 1:2 to isophorone diisocyanate is added dropwise. After the addition is complete, the reaction is carried out for 3 hours. Ethyl acetate is removed by vacuum distillation to obtain modified polyurethane acrylate.

[0017] Furthermore, the modified trimethylolpropane triacrylate is prepared as follows:

[0018] IOTA-8865H, a long-chain alkyl silicone oil with hydroxyl-terminated endosyl groups, and trimethylolpropane triacrylate were added to a reaction vessel at a molar ratio of 1:1. The mixture was heated to 80°C under nitrogen protection, and 0.01% of 4-methoxyphenol and 0.2% of dibutyltin dilaurate were added. After stirring and reacting for 4 hours, modified trimethylolpropane triacrylate was obtained.

[0019] Furthermore, the modified nano-silica is prepared as follows:

[0020] Nano-silica and hexadecyltrimethoxysilane were dispersed in anhydrous ethanol at a mass ratio of 0.5:1, stirred at 90°C for 1 hour, the product was washed with deionized water and filtered, and dried at 60°C for 24 hours to obtain modified nano-silica.

[0021] Furthermore, the leveling agent is MONENG-1060, the defoamer is BYK-052, and the photoinitiator is 1173 photoinitiator.

[0022] Furthermore, the thermoplastic polyurethane resin is a thermoplastic polyurethane resin with a hardness of 80D. The temperature resistance of thermoplastic polyurethane resin (TPU resin) is affected by the proportion of hard segments and soft segments in its molecular structure. Among them, thermoplastic polyurethane (TPU80D resin) with a hardness of 80D has higher strength and heat resistance.

[0023] Furthermore, the bottom layer is a low-foaming polyethylene closed-cell foam board, which has sound insulation effect and excellent waterproof performance.

[0024] This invention also provides a manufacturing process for lightweight molded SPC sheets, comprising the following steps:

[0025] S1. Thermoplastic polyurethane resin and stainless steel fiber are mixed and extruded, and the core layer is obtained after cooling and cutting. The core layer is inserted into the mold as a substrate. Calcium carbonate, polyvinyl chloride resin, calcium zinc stabilizer, titanate coupling agent and stearic acid are mixed and melted, and injected onto the surface of the substrate. After cooling, the substrate is demolded to form a covered substrate layer.

[0026] S2. Apply ink to a PVC film and dry it to obtain a colored film layer;

[0027] S3. Use polyurethane adhesive to attach the color film layer to the upper surface of the substrate layer, and attach the bottom layer to the lower surface of the substrate layer. After pressing with a laminator, cool to 40°C and demold to obtain the main body of the board.

[0028] S4. Mix modified polyurethane acrylate, modified trimethylolpropane triacrylate monomer and modified nano silica, and add photoinitiator, defoamer and leveling agent. After mixing evenly, defoam by ultrasonication and apply to the surface of the main body of the board. Use UV light to cure to form a protective layer to obtain SPC board.

[0029] The beneficial effects of this invention are:

[0030] (1) The core layer is prepared by thermoplastic polyurethane and stainless steel fiber, and the shell layer is prepared by calcium carbonate, polyvinyl chloride and other additives. The thermoplastic polyurethane in the core layer reduces the quality of the substrate layer, and the stainless steel fiber enhances the mechanical properties of the core layer. The thermoplastic polyurethane and polyvinyl chloride in the shell layer have good compatibility and can be well bonded during overmolding.

[0031] (2) Polyurethane acrylate and trimethylolpropane triacrylate monomers are modified with long-chain alkyl silicone oil with dual-terminated alcohol hydroxyl groups, and nano-silica is modified with long-chain siloxane. After mixing the three, a protective layer is formed under photocuring, which has good hydrophobic and wear-resistant properties while having ultraviolet properties. The protective layer, color film layer, substrate layer and bottom layer are combined by lamination process in molding to form an integral board. The board surface is flat and the texture is dense. Attached Figure Description

[0032] The invention will now be further described with reference to the accompanying drawings.

[0033] Figure 1 This is a schematic diagram of the SPC sheet structure according to an embodiment of the present invention.

[0034] In the diagram: 1. Protective layer; 2. Color filter layer; 3. Substrate layer; 4. Bottom layer; 5. Core layer; 6. Shell layer. Detailed Implementation

[0035] The technical solutions of the present invention will be clearly and completely described below with reference to the embodiments of the present invention. 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 of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0036] Example 1

[0037] Isophorone diisocyanate and ethyl acetate were added to a reaction vessel in a mass ratio of 2:5. Then, 0.1% (by weight of isophorone diisocyanate) of 4-methoxyphenol and 0.2% (by weight of isophorone diisocyanate) of 4-methoxyphenol and 0.2% (by weight of isophorone dilaurate) were added. The mixture was stirred and heated to 40°C. Triethylene glycol was added dropwise in a molar ratio of 1:2 to isophorone diisocyanate. After the addition was complete, the reaction was allowed to proceed for 2 hours. The temperature was then raised to 60°C, and IOTA-8865H, a long-chain alkyl silicone oil with hydroxyl groups at the end of its diol, was added dropwise in a molar ratio of 1:4 to isophorone diisocyanate. After the addition was complete, the temperature was raised to 110°C, and the reaction was allowed to proceed for 2 hours. The temperature was then adjusted to 80°C, and hydroxyethyl acrylate was added dropwise in a molar ratio of 1:2 to isophorone diisocyanate. After the reaction was allowed to proceed for 3 hours, ethyl acetate was removed by vacuum distillation to obtain modified polyurethane acrylate.

[0038] IOTA-8865H, a long-chain alkyl silicone oil with two-terminated alcohol hydroxyl groups, and trimethylolpropane triacrylate were added to a reaction vessel at a molar ratio of 1:1. The mixture was heated to 80°C under nitrogen protection, and 0.01% 4-methoxyphenol and 0.2% dibutyltin dilaurate were added by mass of the reactants. After stirring for 4 hours, the modified trimethylolpropane triacrylate monomer was obtained.

[0039] Nano-silica and hexadecyltrimethoxysilane were dispersed in anhydrous ethanol at a mass ratio of 0.5:1, with a reactant mass concentration of 20%. The mixture was stirred at 90°C for 1 hour. The product was washed with deionized water and filtered. After drying at 60°C for 24 hours, modified nano-silica was obtained.

[0040] Example 2

[0041] 98 parts TPU80D resin and 2 parts stainless steel fiber were mixed and extruded, then cooled and cut to obtain the core layer. The core layer was inserted into a mold as a substrate. 65 parts calcium carbonate, 35 parts polyvinyl chloride resin, 5 parts calcium-zinc stabilizer, 1 part titanate coupling agent 201, and 2 parts stearic acid were mixed, melted, and injected onto the substrate surface to form a shell layer. After cooling and demolding, a covered substrate layer was formed. Ink was coated onto a PVC film, and after drying, a colored film layer was obtained.

[0042] A colored film layer is adhered to the upper surface of the substrate layer using polyurethane adhesive, and a low-density polyethylene closed-cell foam board is adhered to the lower surface of the substrate layer. After lamination by a laminator and cooling to 40°C, the board body is demolded to obtain the main body of the board.

[0043] 70 parts of the modified polyurethane acrylate prepared in Example 1, 30 parts of the modified trimethylolpropane triacrylate monomer prepared in Example 1, and 1 part of the modified nano silica prepared in Example 1 were mixed together, and 0.5 parts of 1173 photoinitiator, 0.1 parts of MONENG-1060 leveling agent, and 0.1 parts of BYK-052 defoamer were added. After the above formula was mixed evenly, the bubbles were eliminated by ultrasonication, and the mixture was coated onto the surface of the main body of the board. The protective layer was cured by UV light to obtain the SPC board.

[0044] Example 3

[0045] Compared to Example 2, the amount of modified nano-silica added to the protective layer is 3 parts, and the other steps are the same as in Example 2.

[0046] Example 4

[0047] Compared to Example 2, the amount of modified nano-silica added to the protective layer is 5 parts, and the other steps are the same as in Example 2.

[0048] Example 5

[0049] Compared to Example 2, the amount of stainless steel fiber added to the core layer is 5 parts, and the other steps are the same as in Example 2.

[0050] Example 6

[0051] Compared to Example 2, the amount of stainless steel fiber added to the core layer is 10 parts, and the other steps are the same as in Example 2.

[0052] Examples 7-8

[0053] Compared to Example 2, the weight proportions of each raw material are different, as detailed in Table 1. Other steps are the same as in Example 2.

[0054] Table 1

[0055]

[0056]

[0057] Comparative Example 1

[0058] Compared with Example 2, the substrate layer has no core material and is entirely made of shell material.

[0059] 65 parts calcium carbonate, 35 parts polyvinyl chloride resin, 5 parts calcium zinc stabilizer, 1 part titanate coupling agent 201 and 2 parts stearic acid are mixed, melted, extruded and molded, cooled and cut to form a substrate layer, ink is coated on PVC film, and dried to obtain a colored film layer.

[0060] A colored film layer is adhered to the upper surface of the substrate layer using polyurethane adhesive, and a low-density polyethylene closed-cell foam board is adhered to the lower surface of the substrate layer. After lamination by a laminator and cooling to 40°C, the board body is demolded to obtain the main body of the board.

[0061] 70 parts of the modified polyurethane acrylate prepared in Example 1, 30 parts of the modified trimethylolpropane triacrylate monomer prepared in Example 1, and 1 part of the modified nano silica prepared in Example 1 were mixed together, and 0.5 parts of 1173 photoinitiator, 0.1 parts of MONENG-1060 leveling agent, and 0.1 parts of BYK-052 defoamer were added. After the above formula was mixed evenly, the bubbles were eliminated by ultrasonication, and the mixture was coated onto the surface of the main body of the board. The protective layer was cured by UV light to obtain the SPC board.

[0062] Comparative Example 2

[0063] Compared with Example 2, the protective layer does not use the modified raw materials prepared in Example 1, but directly uses untreated polyurethane acrylate, trimethylolpropane triacrylate monomer and nano silica.

[0064] 98 parts TPU80D resin and 2 parts stainless steel fiber were mixed and extruded, then cooled and cut to obtain the core layer. The core layer was inserted into a mold as a substrate. 65 parts calcium carbonate, 35 parts polyvinyl chloride resin, 5 parts calcium-zinc stabilizer, 1 part titanate coupling agent 201, and 2 parts stearic acid were mixed, melted, and injected onto the substrate surface to form a shell layer. After cooling and demolding, a covered substrate layer was formed. Ink was coated onto a PVC film, and after drying, a colored film layer was obtained.

[0065] A colored film layer is adhered to the upper surface of the substrate layer using polyurethane adhesive, and a low-density polyethylene closed-cell foam board is adhered to the lower surface of the substrate layer. After lamination by a laminator and cooling to 40°C, the board body is demolded to obtain the main body of the board.

[0066] Mix 70 parts polyurethane acrylate, 30 parts trimethylolpropane triacrylate monomer and 1 part nano silica, and add 0.5 parts 1173 photoinitiator, 0.1 parts MONENG-1060 leveling agent and 0.1 parts BYK-052 defoamer. After mixing the above formula evenly, ultrasonically eliminate the bubbles, scrape it onto the surface of the board body, and use UV light to cure it to form a protective layer, thus obtaining SPC board.

[0067] Performance tests were conducted on Examples 1-8 and Comparative Examples 1-2, and the results are shown in Table 2:

[0068] Tested in accordance with GB / T 4085-2015 "Semi-rigid PVC block flooring" standard.

[0069] The contact angle of distilled water on the surface of SPC sheet was measured at room temperature using a contact angle meter.

[0070] Table 2

[0071]

[0072]

[0073] As shown in Table 2, based on Example 2, Examples 2 and 3 added modified nano-silica to the protective layer. The wear resistance initially improved and then decreased; excessive modified nano-silica hindered dispersion, leading to a decrease in wear resistance. Examples 4 and 5 differed from Example 2, increasing the proportion of stainless steel fiber in the core layer of the substrate layer. This helped reduce the deformation of the core layer material at high temperatures, but excessive addition increased the density of the corresponding SPC sheet. Examples 7 and 8 adjusted the raw material ratio, resulting in better overall performance. The substrate layer of Comparative Example 1 had a traditional SPC sheet substrate layer structure, consisting of a single material with high density, but correspondingly better temperature resistance. In the comparative example, the protective layer was a common UV coating without hydrophobic modification, and its waterproof performance was far inferior to that of Example 2.

[0074] 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.

[0075] 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 lightweight molded SPC sheet, characterized in that, From top to bottom, it includes a protective layer (1), a color filter layer (2), a substrate layer (3), and a bottom layer (4). The substrate layer (3) includes a core layer (5) and a shell layer (6); The core layer (5) raw materials include, by weight, 90-98 parts of thermoplastic polyurethane resin and 2-10 parts of stainless steel fiber; The shell (6) raw materials include, by mass parts: 65-80 parts calcium carbonate, 20-35 parts polyvinyl chloride resin, 2-5 parts calcium zinc stabilizer, 1-3 parts titanate coupling agent and 1-2 parts stearic acid. The protective layer (1) comprises, by weight, 70-90 parts of modified polyurethane acrylate, 10-30 parts of modified trimethylolpropane triacrylate, 1-5 parts of modified nano silica, 0.1-0.3 parts of leveling agent, 0.1-0.5 parts of defoamer and 0.5-1 parts of photoinitiator; The modified polyurethane acrylate is a polyurethane acrylate modified with long-chain alkyl silicone oil and dual-terminated alcohol hydroxyl groups. The modified trimethylolpropane triacrylate is a long-chain alkyl silicone oil modified with dual-terminated alcohol hydroxyl groups; The modified nano-silica is long-chain siloxane-modified nano-silica.

2. The lightweight molded SPC sheet according to claim 1, characterized in that, The modified polyurethane acrylate is prepared as follows: S1. Add isophorone diisocyanate and ethyl acetate to the reactor at a mass ratio of 2:5, and add 0.1% of 4-methoxyphenol and 0.2% of dibutyltin dilaurate by mass of isophorone diisocyanate. Stir and heat to 40°C. S2, Triethylene glycol with a molar ratio of 1:2 to isophorone diisocyanate was added dropwise at 40℃, and the reaction was carried out for 2 hours after the addition was completed; S3. Heat to 60℃ and add dropwise IOTA-8865H, a long-chain alkyl silicone oil with a dihydroxyl end of diisocyanate in a molar ratio of 1:4 to isophorone diisocyanate. After the addition is complete, heat to 110℃ and react for 2 hours. S4. After cooling to 80℃, hydroxyethyl acrylate with a molar ratio of 1:2 to isophorone diisocyanate is added dropwise. After the addition is complete, the reaction is carried out for 3 hours. Ethyl acetate is removed by vacuum distillation to obtain modified polyurethane acrylate.

3. The lightweight molded SPC sheet according to claim 1, characterized in that, The modified trimethylolpropane triacrylate is prepared as follows: IOTA-8865H, a long-chain alkyl silicone oil with hydroxyl-terminated endosyl groups, and trimethylolpropane triacrylate were added to a reaction vessel at a molar ratio of 1:

1. The mixture was heated to 80°C under nitrogen protection, and 0.01% of 4-methoxyphenol and 0.2% of dibutyltin dilaurate were added. After stirring and reacting for 4 hours, modified trimethylolpropane triacrylate was obtained.

4. The lightweight molded SPC sheet according to claim 1, characterized in that, The modified nano-silica is prepared as follows: Nano-silica and hexadecyltrimethoxysilane were dispersed in anhydrous ethanol at a mass ratio of 0.5:1 and stirred at 90°C for 1 hour. The product was washed with deionized water and filtered, and then dried at 60°C for 24 hours to obtain modified nano-silica.

5. The lightweight molded SPC sheet according to claim 1, characterized in that, The leveling agent is MONENG-1060, the defoamer is BYK-052, and the photoinitiator is 1173 photoinitiator.

6. The lightweight molded SPC sheet according to claim 1, characterized in that, The thermoplastic polyurethane resin is a thermoplastic polyurethane resin with a hardness of 80D.

7. The lightweight molded SPC sheet according to claim 1, characterized in that, The bottom layer (4) is a low-foaming polyethylene closed-cell foam board.

8. A manufacturing process for lightweight molded SPC sheets as described in any one of claims 1-7, characterized in that, Includes the following steps: S1. After mixing thermoplastic polyurethane resin and stainless steel fiber, the mixture is extruded and then cooled and cut to obtain the core layer (5). The core layer is inserted into the mold as a substrate. Calcium carbonate, polyvinyl chloride resin, calcium zinc stabilizer, titanate coupling agent and stearic acid are mixed and melted, and injected onto the surface of the substrate. After cooling, the substrate is demolded to form a covered substrate layer (3). S2. Apply ink to a PVC film and dry it to obtain a colored film layer (2). S3. Polyurethane adhesive is used to attach the color film layer (2) to the upper surface of the substrate layer (3), and the bottom layer (4) is attached to the lower surface of the substrate layer (3). After lamination, the substrate is cooled to 40°C and demolded to obtain the main body of the board. S4. Mix modified polyurethane acrylate, modified trimethylolpropane triacrylate monomer and modified nano silica, add photoinitiator, defoamer and leveling agent, mix evenly and then scrape onto the surface of the main body of the board, and use UV light to cure to form a protective layer (1) to obtain SPC board.

Images