Production process for PVC bottom-back spliced carpet by using coal gangue

Abstract

The invention discloses a process for producing a PVC (polyvinyl chloride) bottom-back spliced carpet by using coal gangue, which comprises the following steps of: 1, pretreating the coal gangue, crushing the coal gangue, screening, and cleaning to remove impurities; 2, modification treatment, wherein the surfaces of the coal gangue particles are combined with the PVC material through treatment of a modifier; step 3, preparation of a PVC composite material: mixing the modified coal gangue and PVC resin in proportion, and uniformly stirring through a high-speed mixer; according to the process, the coal gangue is used as filler, use of traditional filler is reduced, pollution of the coal gangue to the environment is relieved, the coal gangue is low in cost, the production cost of the PVC carpet can be greatly reduced after mineral filler is replaced, the coal gangue subjected to surface modification is firmly combined with PVC, and the PVC carpet is not prone to cracking. And the impact resistance, the compression resistance and the tensile resistance of the composite material are superior to those of the traditional bottom back material.

Description

Technical Field

[0001] The invention relates to a production process of a back mosaic carpet, in particular to a production process of using coal gangue for a PVC back mosaic carpet, belonging to the technical field of production of building decoration materials. Background Art

[0002] In the carpet manufacturing process, the filler selection of PVC backing tile carpet is crucial. Commonly used fillers include heavy calcium carbonate, silane coupling agent modified mineral powder, etc. However, these traditional filler technologies still have many shortcomings in practical applications, resulting in product performance that is difficult to fully meet market demand.

[0003] First, traditional fillers such as heavy calcium carbonate have poor compatibility with PVC resin. The filler and resin are not well bonded after mixing, and the filler is prone to fall off. This directly affects the wear resistance of the carpet, making traditional carpets prone to wear and tear during long-term use and having poor durability. Moreover, due to insufficient bonding force, the compressive strength of the carpet is also limited, making it difficult to withstand large external forces, which is particularly prominent in heavy-load use scenarios.

[0004] Secondly, although the existing silane coupling agent modification process has improved the dispersibility of fillers and the adhesion to resins to a certain extent, its processing process is cumbersome and complicated, and the modification effect is also affected by the process stability, resulting in a significant increase in material costs. In addition, the silane coupling agent processing process is not environmentally friendly, and the emission of volatile organic compounds is likely to pollute the air, causing potential harm to the ecological environment and workers' health.

[0005] Therefore, the traditional technology is not only insufficient in wear resistance and compressive strength, but also has high cost and poor environmental performance. To this end, the present invention proposes a production process for PVC backing patchwork carpet with coal gangue modified filler, striving to improve the durability, mechanical properties and environmental performance of the carpet while keeping the cost low, thereby effectively making up for the shortcomings of the traditional technology. Summary of the invention

[0006] The purpose of the present invention is to provide a production process for PVC backing mosaic carpet using coal gangue, and a high-strength and low-cost PVC backing mosaic carpet is prepared by pre-treating the coal gangue, modifying the surface, uniformly mixing and composite pressing the coal gangue. The present invention realizes the close combination of coal gangue and PVC material, improves the impact resistance and tensile strength of the composite material, and makes it meet the use requirements of the carpet backing layer.

[0007] To achieve the above object, the present invention provides the following technical solution: a production process of using coal gangue for PVC backing mosaic carpet, the production process of using coal gangue for PVC backing mosaic carpet comprising the following steps: Step 1: Pretreatment of coal gangue, crushing the coal gangue, screening and washing to remove impurities; Step 2: Modification treatment, using a modifier to combine the surface of the gangue particles with the PVC material; Step 3: Preparation of PVC composite material: Mix the modified coal gangue and PVC resin in proportion and stir them evenly by a high-speed mixer; Step 4: Backing layer compounding: evenly spread the PVC composite material on the substrate, and perform high temperature pressing at 180-200°C to obtain the finished carpet backing layer.

[0008] As a preferred technical solution of the present invention, the particle size of the coal gangue is controlled between 20-50 meshes.

[0009] As a preferred technical solution of the present invention, the modifier is a silane coupling agent.

[0010] As a preferred technical solution of the present invention, in step three, 20-30% of a plasticizer is added during the mixing process to increase the flexibility of the composite material.

[0011] As a preferred technical solution of the present invention, in step three, the mass ratio of coal gangue to PVC in the PVC composite material is between 1:4 and 1:6.

[0012] As a preferred technical solution of the present invention, in the step 4, during the back layer composite process, the temperature is controlled at 180-200°C for 30-50 minutes to ensure the stability of the composite material.

[0013] As a preferred technical solution of the present invention, the surface of the bottom back layer is coated with an anti-slip coating.

[0014] Compared with the prior art, the beneficial effects of the present invention are as follows: the present invention provides a production process for using coal gangue for PVC backing mosaic carpets. The process uses coal gangue as filler, reduces the use of traditional fillers, and alleviates the pollution of coal gangue to the environment. The cost of coal gangue is low, and after replacing mineral fillers, the production cost of PVC carpets can be greatly reduced. The surface-modified coal gangue is firmly combined with PVC, so that the impact resistance, compression resistance and tensile resistance of the composite material are better than those of traditional backing materials. DETAILED DESCRIPTION

[0015] The technical solutions in the embodiments of the present invention are described clearly and completely. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0016] The present invention provides a production process for using coal gangue for PVC backing mosaic carpet tiles, and the production process for using coal gangue for PVC backing mosaic carpet tiles comprises the following steps: Step 1: Pretreatment of coal gangue, crushing the coal gangue, screening and washing to remove impurities; Step 2: Modification treatment, using a modifier to combine the surface of the gangue particles with the PVC material; Step 3: Preparation of PVC composite material: Mix the modified coal gangue and PVC resin in proportion and stir them evenly by a high-speed mixer; Step 4: Backing layer compounding: evenly spread the PVC composite material on the substrate, and perform high temperature pressing at 180-200°C to obtain the finished carpet backing layer.

[0017] Wherein, the particle size of the coal gangue is controlled between 20-50 meshes.

[0018] Furthermore, the modifier is a silane coupling agent.

[0019] Furthermore, in step three, 20-30% of a plasticizer is added during the mixing process to increase the flexibility of the composite material.

[0020] Wherein, in the step 3, the mass ratio of coal gangue to PVC in the PVC composite material is between 1:4 and 1:6.

[0021] Preferably, in the step 4, during the process of compounding the bottom and back layers, the temperature is controlled at 180-200° C. for 30-50 minutes to ensure the stability of the composite material.

[0022] Wherein, the surface of the bottom back layer is coated with an anti-slip coating.

[0023] Embodiment 1: Raw material processing: Use untreated heavy calcium carbonate as filler and crush it to 60 mesh; Material mixing: Mix heavy calcium carbonate and PVC resin in a mass ratio of 1:5, add plasticizer, and mix for 10 minutes; Molding process: Press the mixture at 180°C for 30 minutes; Anti-slip treatment: spray a simple anti-slip coating on the back layer; Product features: The carpet produced by this method has low cost, but the bonding between the filler and the PVC resin is average, the wear resistance and compressive strength of the product are weak, and the service life is short.

[0024] Embodiment 2: Raw material processing: Mineral powder (such as quartz sand) crushed to 50 mesh is used as filler, and treated with silane coupling agent for 30 minutes to enhance its bonding with PVC; Material mixing: Mix the modified mineral powder and PVC resin in a ratio of 1:4, add 25% plasticizer, and mix for 15 minutes; Molding process: Pressing at 190℃ for 40 minutes, the finished product has good compactness; Anti-slip treatment: spray high-quality anti-slip coating evenly on the surface of the carpet backing layer; Product features: Compared with Example 1, this method improves the dispersibility of the mineral filler and the bonding strength with the resin, making the carpet have better wear resistance and durability, but the filler processing process is complicated and the cost is increased.

[0025] Embodiment three: Raw material processing: The coal gangue is crushed to 40 mesh, surface modified with silane coupling agent for 45 minutes, and then washed and dried.

[0026] Material mixing: Add modified coal gangue to PVC resin in a mass ratio of 1:4, add 20% plasticizer, and stir for 20 minutes to ensure uniform distribution.

[0027] Molding process: Pressing and molding at 200℃ and high temperature and high pressure for 50 minutes to ensure the density and stability of the carpet.

[0028] Anti-slip treatment: After molding, a special anti-slip coating is evenly sprayed on the back layer to give the carpet excellent anti-slip performance.

[0029] Product features: The carpet produced by the method of the present invention not only improves the bonding strength between coal gangue and PVC resin, but also significantly improves the wear resistance, compressive strength and environmental performance of the product. Compared with traditional fillers, the coal gangue processing process of the present invention: In this embodiment, the present invention crushes the coal gangue to 40 mesh, and uses a silane coupling agent for 30 minutes for modification treatment, and washes the impurities with water and then dries. The prior art mostly uses untreated mineral powder fillers, while the modified coal gangue filler of the present invention overcomes the problem of poor adhesion caused by the strong hydrophobicity of the coal gangue surface, thereby ensuring the close bonding of the filler and the substrate.

[0030] Preparation of composite material: Coal gangue and PVC resin are mixed in a mass ratio of 1:4, 20% plasticizer is added, and high-speed stirring equipment is used to ensure uniform distribution. Mineral powder fillers in the prior art are often difficult to disperse evenly during the mixing process, resulting in insufficient compression resistance of the finished carpet. Through the treatment of the present invention, the modified coal gangue filler is fully integrated with the PVC resin, so that the compression and bending resistance of the composite material are significantly enhanced.

[0031] Improved molding process: The present invention adopts a 200°C temperature and 50-minute pressing molding process, so that the composite material can achieve an ideal molding effect under high temperature and high pressure. In the prior art, in order to avoid high-temperature deformation of the filler, the molding temperature is usually controlled at 150-160°C, and the pressing time is short, resulting in insufficient density of the finished material. Through the molding process of the present invention, the composite material structure is more stable and can maintain good physical properties in long-term use. It reduces costs while maintaining high performance.

[0032] Data comparison: Example 1: Prior art 1 (traditional filler) Example 2: Prior art 2 (modified mineral powder) Example 3: The present invention (gangue modified filler) Comparative Analysis 1. Wear resistance: Example 3 has the highest wear resistance, reaching a service life of 10,000 times, while Examples 1 and 2 are 5,000 and 8,000 times respectively. Through the modification of coal gangue and a reasonable molding process, the present invention achieves higher product durability.

[0033] 2. Compressive strength: The compressive strength of the method in Example 3 is the highest, reaching 40 MPa, which is significantly better than the prior art. This shows that the carpet produced by the process of the present invention is more durable in a high-load environment.

[0034] 3. Cost: The cost of the method of the present invention is 55 yuan / square meter, which is slightly higher than that of Example 1 but lower than that of Example 2. By using coal gangue as filler, the present invention effectively reduces the material cost and avoids the complicated treatment in the traditional mineral powder modification process.

[0035] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A production process for using coal gangue for PVC backing tile carpet, characterized in that: The production process of using coal gangue for PVC backing tile carpet comprises the following steps: Step 1: Pretreatment of coal gangue, crushing the coal gangue, screening and washing to remove impurities; Step 2: Modification treatment, using a modifier to combine the surface of the gangue particles with the PVC material; Step 3: Preparation of PVC composite material: Mix the modified coal gangue and PVC resin in proportion and stir them evenly by a high-speed mixer; Step 4: Backing layer compounding: evenly spread the PVC composite material on the substrate, and perform high temperature pressing at 180-200°C to obtain the finished carpet backing layer.

2. The production process of using coal gangue for PVC backing carpet tiles according to claim 1, characterized in that: The particle size of the coal gangue is controlled between 20-50 meshes.

3. The production process of using coal gangue for PVC backing carpet tiles according to claim 1, characterized in that: The modifier is a silane coupling agent.

4. The production process of using coal gangue for PVC backing carpet tiles according to claim 1, characterized in that: In the step three, 20-30% of a plasticizer is added during the mixing process to increase the flexibility of the composite material.

5. The production process of using coal gangue for PVC backing carpet tiles according to claim 1, characterized in that: In the step 3, the mass ratio of the coal gangue to the PVC in the PVC composite material is between 1:4 and 1:

6.

6. The production process of using coal gangue for PVC backing carpet tiles according to claim 1, characterized in that: In the step 4, during the back layer compounding process, the temperature is controlled at 180-200° C. for 30-50 minutes to ensure the stability of the composite material.

7. The production process of using coal gangue for PVC backing carpet tiles according to claim 1, characterized in that: The surface of the bottom back layer is coated with an anti-slip coating.

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