Polypropylene plastic floor and manufacturing method thereof

Abstract

The invention discloses a plastic floor made of polypropylene and a preparation method thereof, the floor is composed of a plurality of floor units, each floor unit is composed of a surface UV coating, a PP transparent wear-resistant layer, a hot melt adhesive film layer, a PP printing decoration layer, a middle layer and a PP composite backing material layer, the hot melt adhesive film layer is made of one or more of EVA, PA, PES, PO and TPU, and the PP composite backing material layer is made of polypropylene. And the hot melt adhesive film layer is manufactured into a single layer through hot-pressing lamination or is directly coated on the back surface of the PP transparent wear-resistant layer. The hot melt adhesive film layer adopted by the floor is independently customized and purchased, the back face of the PP transparent wear-resistant layer can be coated with hot melt adhesive, production can be conducted through traditional hot pressing, multi-layer hot attaching, extrusion re-attaching and other technologies, machining operation is convenient, attaching of all the layers is very firm, and compared with an existing PP plastic floor in the market, the floor has the advantages that the floor is more attractive, and the floor is more environmentally friendly and free of pollution. The product manufacturing cost is lower, the production process is mature and stable, the production efficiency and the yield are high, and large-batch production can be achieved.

Description

Technical Field

[0001] The invention relates to the technical field of flooring, and in particular to a plastic flooring made of polypropylene and a manufacturing method thereof. Background Art

[0002] The mainstream materials used in the current market for plastic flooring are PVC and rubber. Flooring can be basically divided into two categories: sheet and roll. Sheet flooring is basically semi-rigid ordinary flooring and buckle-type lock flooring. Currently, the sheet flooring field basically uses PVC material. The non-PVC material flooring on the market now includes PET material, PP material, TPU material, etc., with a thickness between 2.0-6.0mm.

[0003] The main problem facing plastic floors made of PET, PP and other materials on the current market is the bonding problem between the printed color film used and the transparent surface layer. The traditional PVC material flooring process and its various production materials are very compatible. The surface PVC transparent wear-resistant layer and the PVC printed color film as well as the PVC composite substrate layer below can be pressed and formed at one time regardless of whether the hot pressing process or the popular extrusion process is used. The various layers of the product are firmly bonded to each other. For existing non-PVC material flooring products such as PP materials, the surface PP wear-resistant layer and the PP printed color film below are bonded together through composite pressing. The produced PP plastic floors generally have a low bonding strength between the two materials and are prone to stratification.

[0004] In addition, existing PP floor products use a material that is a combination of a PP transparent wear-resistant layer and a PP printed layer that are completely compounded. This has great limitations when mass-producing products. The specifications and patterns of the surface PP wear-resistant layer and the PP printed color film are fixed. When producing products with various specifications and thicknesses, more materials are required, resulting in a great waste of production costs and storage space. In addition, the PP transparent layer and PP printed color film require manufacturers to have the ability to produce two materials at the same time, or to purchase the two materials for secondary compounding, which invisibly increases production and transportation costs. Summary of the invention

[0005] The object of the present invention is to provide a plastic floor made of polypropylene and a manufacturing method thereof, so as to solve the problems raised in the above-mentioned background technology.

[0006] A plastic floor made of polypropylene is composed of a plurality of floor units, wherein the floor units are composed of a surface UV coating, a PP transparent wear-resistant layer, a hot-melt adhesive film layer, a PP printed decorative layer, an intermediate layer and a PP composite base material layer, wherein the material of the hot-melt adhesive film layer is one or more of EVA, PA, PES, PO and TPU, and the hot-melt adhesive film layer is made into a single layer by hot pressing or directly coated on the back of the PP transparent wear-resistant layer.

[0007] Furthermore, the hot melt adhesive film layer has a thickness of 0.02-0.3 mm.

[0008] Furthermore, the middle layer is a PP composite middle material layer.

[0009] Furthermore, the middle layer is composed of two PP composite middle material layers and one composite glass fiber layer, and the composite glass fiber layer is located between the two PP composite middle material layers; the PP composite middle material layer contains chopped glass fibers, and the chopped glass fiber content is 2-25% by weight; the composite glass fiber layer is a glass fiber layer, a mesh glass fiber layer or a composite glass fiber chopped mat, or a glass fiber layer coated with a film or paste resin, and the weight range is 15g-400g.

[0010] Furthermore, an adhesive layer and a sound reduction layer are sequentially arranged on the back side of the PP composite base material layer.

[0011] Furthermore, the material of the adhesive layer includes one or more of hot melt adhesive, two-component adhesive, and PUR thermosetting adhesive, the material of the sound reduction layer includes one or more of chemical fiber cloth, IXPE, EVA, and cork, and the thickness of the sound reduction layer is 0.5-3 mm.

[0012] A method for making a polypropylene plastic floor comprises the following steps:

[0013] 1) Preparing the PP composite middle material layer: mixing PP particles, plasticizer, heat stabilizer, color powder, and filler materials according to 90-99 parts, 0.1-10 parts, 0.1-3 parts, 0-1 parts, and 180-400 parts by weight for 30-3000s, and kneading for 60-300s, and then calendering at 130-170°C to produce a sheet with a thickness of 0.2-3mm, a length of ≥0.5m, and a width of 0.5-2m, and adding chopped glass fibers, wherein the chopped glass fiber content accounts for 2-25% by weight;

[0014] 2) Preparing the PP composite base material layer: mixing PP particles, plasticizer, heat stabilizer, color powder, and filler material according to 90-99 parts by weight, 0.1-10 parts, 0.1-3 parts, 0-1 parts, and 0-400 parts by weight for 30-3000 seconds, kneading for 60-300 seconds, and then calendering at 130-170° C. to produce a sheet with a thickness of 0.2-3 mm, a length of ≥0.5 m, and a width of 0.5-2 m;

[0015] 3) The PP transparent wear-resistant layer, the hot-melt adhesive film layer, the PP printed decorative layer and the middle layer, and the PP composite base material layer are sequentially formed by flat-plate vulcanization hot pressing, or laminated by a multi-layer heat laminating machine, or produced by extrusion equipment, first heated and then cold processed into a product, and then subjected to surface UV treatment to obtain a UV coating, and then subjected to a tempering process for heat and cold treatment to stabilize the thermal shrinkage performance of the product, and the finished floor is prepared by molding.

[0016] Furthermore, the filling materials in step 1) and step 2) include calcium carbonate and a flame retardant, and the flame retardant is magnesium hydroxide.

[0017] Furthermore, the middle layer in step 3) is the PP composite middle material layer prepared in step 1), or the middle layer in step 3) is two PP composite middle material layers prepared in step 1) and one composite glass fiber layer, and the composite glass fiber layer is located between the two PP composite middle material layers.

[0018] Furthermore, in step 3), after the product is subjected to heat and cold treatment through a tempering process to stabilize its thermal shrinkage performance, the sound reduction layer is bonded to the back side through an adhesive layer, and after the sound reduction layer is firmly bonded to the back side of the semi-finished product, a standard floor product is prepared through molding processing.

[0019] Compared with the prior art, the present invention has the following beneficial effects:

[0020] 1. The hot melt adhesive film layer used in the present invention can be independently customized and purchased, or the hot melt adhesive can be coated on the back of the PP transparent wear-resistant layer. It can be produced by traditional hot pressing, multi-layer hot lamination, extrusion lamination and other processes. The processing operation is convenient, and the lamination between the layers is also very firm;

[0021] 2. The floor of the present invention has the same functions as the traditional PVC floor, such as non-toxic, odorless, environmentally friendly, durable, non-slip, waterproof, sound-absorbing, and rich in color;

[0022] 3. Compared with the existing PP plastic floor on the market, the floor of the present invention has lower manufacturing cost, mature and stable production process, high production efficiency and yield rate, and can be produced in large quantities;

[0023] 4. The product of the present invention has a high recycling rate and does not have the problem of difficult recycling. The processing scraps in the production process of this product can be directly recycled and reused, without the need to be crushed and ground like other non-PVC material floors before a small amount of recycling;

[0024] 5. The material applicability of the product of the present invention is wide, and the material supply chain is wide;

[0025] 6. Flame retardant materials are added to the product formula of the present invention, which can effectively improve the defects of PP material itself. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 This is a schematic diagram of the product structure of Embodiments 1-3 of the present invention;

[0027] Figure 2 This is a schematic diagram of the product structure of Example 4 of the present invention;

[0028] Figure 3 This is a schematic diagram of the product structure of Example 5 of the present invention;

[0029] Figure 4 This is a schematic diagram of the product structure of Example 6 of the present invention;

[0030] In the figure: 1-surface UV coating; 2-PP transparent wear-resistant layer; 3-hot melt adhesive film layer; 4-PP printed decorative layer; 5-PP composite middle material layer; 6-PP composite base material layer; 7-adhesive layer; 8-sound reduction layer; 9-composite glass fiber layer. DETAILED DESCRIPTION

[0031] The technical solution of the present invention is described in more detail below in conjunction with specific implementations and drawings.

[0032] Example 1

[0033] A plastic floor made of polypropylene, composed of multiple floor units, the floor unit consists of a surface UV coating 1, a PP transparent wear-resistant layer 2, a hot melt adhesive film layer 3, a PP printed decorative layer 4, an intermediate layer and a PP composite base material layer 6. The material of the hot melt adhesive film layer is one or more of EVA, PA, PES, PO, and TPU. The hot melt adhesive film layer 3 is made into a single layer by hot pressing or directly coated on the back of the PP transparent wear-resistant layer. The film thickness of the hot melt adhesive film layer is 0.02mm. The PP composite middle material layer 5 contains chopped glass fibers, and the chopped glass fiber content accounts for 2% by weight;

[0034] The method for making the polypropylene plastic floor comprises the following steps:

[0035] 1) Preparing the PP composite middle material layer 5: PP particles, plasticizer, heat stabilizer, and filler material are mixed according to 90 parts by weight, 9.9 parts by weight, 0.1 parts by weight, and 180 parts by weight, and kneaded for 60 seconds, and then rolled into sheets at 130° C., the sheet thickness is 0.2 mm, the sheet length is 0.5 m, the sheet width is 0.5 m, and short chopped glass fibers are added; the filler material includes calcium carbonate and a flame retardant, and the flame retardant is magnesium hydroxide;

[0036] 2) Preparation of PP composite base material layer 6: 90 parts, 9.9 parts, 0.1 parts, and 180 parts were mixed for 30 seconds, kneaded for 60 seconds, and then calendered at 130° C. to produce a sheet with a thickness of 0.2 mm, a length of 0.5 m, and a width of 0.5 m;

[0037] 3) The PP transparent wear-resistant layer 2, the hot-melt adhesive film layer 3, the PP printed decorative layer 4, the PP composite middle material layer 5, and the PP composite base material layer 6 are sequentially formed by flat-plate vulcanization hot pressing, or laminated by a multi-layer heat laminating machine, or produced by extrusion equipment, first heated and then cold processed into a product, and then subjected to surface UV treatment to obtain a UV coating 1, and then subjected to a tempering process for heat and cold treatment to stabilize the thermal shrinkage performance of the product, and the finished floor is prepared by molding.

[0038] Example 2

[0039] A polypropylene plastic floor, composed of multiple floor units, the floor unit is composed of a surface UV coating 1, a PP transparent wear-resistant layer 2, a hot melt adhesive film layer 3, a PP printed decorative layer 4, an intermediate layer and a PP composite base material layer 6. The material of the hot melt adhesive film layer is one or more of EVA, PA, PES, PO, and TPU. The hot melt adhesive film layer 3 is made into a single layer by hot pressing or directly coated on the back of the PP transparent wear-resistant layer. The film thickness of the hot melt adhesive film layer is 0.15mm. The PP composite middle material layer 5 contains chopped glass fibers, and the chopped glass fiber content accounts for 15% by weight;

[0040] The method for making the polypropylene plastic floor comprises the following steps:

[0041] 1) Preparing the PP composite middle material layer 5: PP particles, plasticizer, heat stabilizer, color powder, and filler material are mixed according to 95 parts, 2 parts, 1.5 parts, 0.5 parts, and 300 parts by weight for 1200 seconds, kneaded for 180 seconds, and then rolled into sheets at 150° C. The sheet thickness is 1.5 mm, the sheet length is 0.7 m, and the sheet width is 1.2 m. Short chopped glass fibers are added; the filler material includes calcium carbonate and a flame retardant, and the flame retardant is magnesium hydroxide;

[0042] 2) Preparing PP composite base material layer 6: PP particles, plasticizer, heat stabilizer, color powder, and filler material are mixed according to 95 parts, 2 parts, 1.5 parts, 0.5 parts, and 300 parts by weight for 1200 seconds, kneaded for 180 seconds, and then rolled at 150° C. to produce a sheet with a thickness of 1.5 mm, a length of 0.7 m, and a width of 1.2 m;

[0043] 3) The PP transparent wear-resistant layer 2, the hot-melt adhesive film layer 3, the PP printed decorative layer 4, the PP composite middle material layer 5, and the PP composite base material layer 6 are sequentially formed by flat-plate vulcanization hot pressing, or laminated by a multi-layer heat laminating machine, or produced by extrusion equipment, first heated and then cold processed into a product, and then subjected to surface UV treatment to obtain a UV coating 1, and then subjected to a tempering process for heat and cold treatment to stabilize the thermal shrinkage performance of the product, and the finished floor is prepared by molding.

[0044] Example 3

[0045] A polypropylene plastic floor, composed of multiple floor units, the floor unit is composed of a surface UV coating 1, a PP transparent wear-resistant layer 2, a hot melt adhesive film layer 3, a PP printed decorative layer 4, an intermediate layer and a PP composite base material layer 6. The material of the hot melt adhesive film layer is one or more of EVA, PA, PES, PO, and TPU. The hot melt adhesive film layer 3 is made into a single layer by hot pressing or directly coated on the back of the PP transparent wear-resistant layer. The film thickness of the hot melt adhesive film layer is 0.02-0.3mm. The PP composite middle material layer 5 contains chopped glass fibers, and the chopped glass fiber content accounts for 2-25% by weight;

[0046] The method for making the polypropylene plastic floor comprises the following steps:

[0047] 1) Preparing the PP composite middle material layer 5: PP particles, plasticizer, heat stabilizer, color powder, and filler material are mixed according to 99 parts by weight, 0.1 parts, 0.1 parts, 0.8 parts, and 400 parts by weight for 3000 seconds, and kneaded for 300 seconds, and then rolled out at 170° C. The sheet thickness is 3 mm, the sheet length is 0.7 m, and the sheet width is 2 m, and short chopped glass fibers are added; the filler material includes calcium carbonate and a flame retardant, and the flame retardant is magnesium hydroxide;

[0048] 2) Preparing PP composite base material layer 6: PP particles, plasticizer, heat stabilizer, color powder, and filler material are mixed according to 99 parts by weight, 0.1 parts, 0.1 parts, 0.8 parts, and 400 parts by weight for 3000 seconds, kneaded for 300 seconds, and then rolled at 170° C. to produce a sheet with a thickness of 3 mm, a length of 0.7 m, and a width of 2 m;

[0049] 3) The PP transparent wear-resistant layer 2, the hot-melt adhesive film layer 3, the PP printed decorative layer 4, the PP composite middle material layer 5, and the PP composite base material layer 6 are sequentially formed by flat-plate vulcanization hot pressing, or laminated by a multi-layer heat laminating machine, or produced by extrusion equipment, first heated and then cold processed into a product, and then subjected to surface UV treatment to obtain a UV coating 1, and then subjected to a tempering process for heat and cold treatment to stabilize the thermal shrinkage performance of the product, and the finished floor is prepared by molding.

[0050] Example 4

[0051] The composition of a polypropylene plastic floor and steps 1) and 2) in the production method are the same as those in Example 2, and step 3) in the production method is replaced by:

[0052] 3) The PP transparent wear-resistant layer 2, the hot-melt adhesive film layer 3, the PP printed decorative layer 4, the PP composite middle material layer 5, and the PP composite base material layer 6 are sequentially formed by flat vulcanization hot pressing, or laminated by a multi-layer heat laminating machine, or produced by extrusion equipment, first heated and then cold processed into a product, and then subjected to surface UV treatment to obtain a UV coating 1, and then subjected to a tempering process for heat and cold treatment to stabilize the thermal shrinkage performance of the product, and the back side of the product is bonded to the sound reduction layer 8 by an adhesive layer 7, and after the sound reduction layer 8 is firmly bonded to the back side of the semi-finished product, a standard floor product is prepared by molding.

[0053] Example 5

[0054] The composition of a polypropylene plastic floor and steps 1) and 2) in the production method are the same as those in Example 2, and step 3) in the production method is replaced by:

[0055] 3) The PP transparent wear-resistant layer 2, the hot-melt adhesive film layer 3, the PP printed decorative layer 4, the PP composite middle material layer 5, the composite glass fiber layer 9, the composite middle material layer 5, and the PP composite base material layer 6 are sequentially formed by flat-plate vulcanization hot pressing, or laminated by a multi-layer heat laminating machine, or produced by extrusion equipment, first heated and then cold processed into a product, and then subjected to surface UV treatment to obtain a UV coating 1, and then subjected to a tempering process for heat and cold treatment to stabilize the thermal shrinkage performance of the product, and the finished floor is prepared by molding.

[0056] Example 6

[0057] The composition of a polypropylene plastic floor and steps 1) and 2) in the production method are the same as those in Example 2, and step 3) in the production method is replaced by:

[0058] 3) The PP transparent wear-resistant layer 2, the hot melt adhesive film layer 3, the PP printed decorative layer 4, the PP composite middle material layer 5, the composite glass fiber layer 9, the composite middle material layer 5, and the PP composite bottom material layer 6 are sequentially formed by flat vulcanization hot pressing, or by using a multi-layer hot laminating machine for laminating, or by extrusion equipment, and are first hot-processed and then cold-processed into a product, and then subjected to surface UV treatment to obtain a UV coating 1, and then subjected to a tempering process for heat and cold treatment to stabilize the thermal shrinkage performance of the product, and the back side thereof is bonded with the sound reduction layer 8 through the adhesive layer 7, and after the sound reduction layer 8 is firmly bonded to the back side of the semi-finished product, a standard floor product is prepared by molding. The composite glass fiber layer 9 is a glass fiber layer, a mesh glass fiber layer, or a composite glass fiber chopped strand mat, or a glass fiber layer coated with a film or a paste resin, and the gram weight range is 200g.

[0059] The polypropylene plastic floor product of the present invention can have a layer of hot-melt pressure-sensitive adhesive pasted on the back sound-reducing layer 8 to make the product installation more convenient. A release paper is pasted on the back of the pressure-sensitive adhesive, and the release paper can be removed during construction for quick installation.

[0060] The present invention adopts the existing hot melt adhesive film processing technology, uses the adhesive film as a medium to make a hot melt adhesive film layer 3, and completely and firmly bonds the upper and lower layers of the same or different materials through thermal bonding. The materials of each layer used in the present invention do not need to be compounded in advance, and can be equipped with various specifications of materials according to customer requirements. The hot melt adhesive film layer 3 used in the present invention can be independently customized and purchased, and the hot melt adhesive can also be coated on the back of the PP transparent wear-resistant layer 2. The process is very mature, and the selection of material manufacturers and the supply chain of the entire product are very sound.

Claims

1. A polypropylene plastic floor, characterized in that: The invention is composed of a plurality of floor units, wherein the floor units are composed of a surface UV coating (1), a PP transparent wear-resistant layer (2), a hot-melt adhesive film layer (3), a PP printed decorative layer (4), an intermediate layer and a PP composite base material layer (6). The material of the hot-melt adhesive film layer is one or more of EVA, PA, PES, PO and TPU. The hot-melt adhesive film layer is made into a single layer by hot pressing or directly coated on the back of the PP transparent wear-resistant layer.

2. The polypropylene plastic floor according to claim 1, characterized in that: The hot melt adhesive film layer (3) has a thickness of 0.02-0.3 mm.

3. The polypropylene plastic floor according to claim 1, characterized in that: The middle layer is a PP composite middle material layer (5).

4. The polypropylene plastic floor according to any one of claims 1 to 3, characterized in that: The middle layer is composed of two PP composite middle material layers (5) and one composite glass fiber layer (9), wherein the composite glass fiber layer (9) is located between the two PP composite middle material layers (5); the PP composite middle material layer (5) contains chopped glass fibers, and the chopped glass fibers account for 2-25% by weight; the composite glass fiber layer (9) is a glass fiber layer, a mesh glass fiber layer or a composite glass fiber chopped mat, or a glass fiber layer coated with a film or a paste resin, and the weight ranges from 15g to 400g.

5. The polypropylene plastic floor according to any one of claims 1 to 3, characterized in that: An adhesive layer (7) and a sound reduction layer (8) are sequentially arranged on the back of the PP composite base material layer.

6. The polypropylene plastic floor according to any one of claim 5, characterized in that: The material of the adhesive layer (7) includes one or more of hot melt adhesive, two-component adhesive, and PUR thermosetting adhesive. The material of the sound reduction layer (8) includes one or more of chemical fiber cloth, IXPE, EVA, and cork. The thickness of the sound reduction layer (8) is 0.5-3 mm.

7. A method for manufacturing a polypropylene plastic floor as claimed in any one of claims 1 to 3, characterized in that: The steps include: 1) preparing a PP composite middle material layer (5): mixing PP particles, a plasticizer, a heat stabilizer, a color powder, and a filler material in the amounts of 90-99 parts, 0.1-10 parts, 0.1-3 parts, 0-1 parts, and 180-400 parts by weight for 30-3000 seconds, kneading for 60-300 seconds, and then rolling out a sheet at 130-170° C., wherein the sheet thickness is 0.2-3 mm, the sheet length is ≥0.5 m, and the sheet width is 0.5-2 m, and short glass fibers are added, wherein the short glass fibers have a gram weight percentage of 2-25%; 2) preparing a PP composite base material layer (6): mixing PP particles, a plasticizer, a heat stabilizer, a color powder, and a filler material in the amounts of 90-99 parts, 0.1-10 parts, 0.1-3 parts, 0-1 parts, and 0-400 parts by weight for 30-3000 seconds, kneading for 60-300 seconds, and then calendering the mixture at 130-170° C. to produce a sheet with a thickness of 0.2-3 mm and a length of ≥0.5 m; 3) The PP transparent wear-resistant layer (2), the hot-melt adhesive film layer (3), the PP printed decorative layer (4), the middle layer, and the PP composite base material layer (6) are sequentially formed by flat-plate vulcanization hot pressing, or laminated by a multi-layer heat laminating machine, or produced by extrusion equipment, first heated and then cold processed into a product, and then subjected to surface UV treatment to obtain a UV coating (1), and then subjected to a tempering process for heat and cold treatment to stabilize the thermal shrinkage performance of the product, and the finished floor is prepared by molding.

8. The method for making a polypropylene plastic floor according to claim 7, characterized in that: The filling materials in step 1) and step 2) include calcium carbonate and a flame retardant, and the flame retardant is magnesium hydroxide.

9. The method for manufacturing a polypropylene plastic floor according to claim 7, characterized in that: The middle layer in step 3) is the PP composite middle material layer (5) prepared in step 1), or the middle layer in step 3) is two layers of the PP composite middle material layer (5) prepared in step 1) and one layer of composite glass fiber layer (9), and the composite glass fiber layer (9) is located between the two layers of the PP composite middle material layer (5).

10. The method for manufacturing a polypropylene plastic floor according to claim 7, characterized in that: In the step 3), after the product is subjected to heat and cold treatment through a tempering process to stabilize its thermal shrinkage performance, the back side thereof is bonded to the sound reduction layer (8) through an adhesive layer (7), and after the sound reduction layer (8) is firmly bonded to the back side of the semi-finished product, a standard floor product is prepared through a molding process.

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