Toughened impact-resistant multi-layer composite decorative plate and preparation method thereof

Abstract

The invention discloses a toughened impact-resistant multi-layer composite decorative plate and a preparation method thereof, and belongs to the technical field of decorative plates. The composite decorative plate comprises a foaming fiberboard layer, an upper stone-plastic plate layer and a lower stone-plastic plate layer which are arranged on the upper surface and the lower surface of the foaming fiberboard layer, and a decorative surface layer arranged on the upper surface of the upper stone-plastic plate layer, the foaming fiberboard layer is prepared from the following raw materials in parts by mass: 25 parts of 8-type PVC resin powder; 30 to 45 parts of calcium powder; 5-20 parts of chopped glass fiber powder; 1-2 parts of a stabilizer; 0.5-1 part of a foaming agent; 3-5 parts of a foaming regulator; 0.1 to 0.3 part of polyethylene wax; 0.1 to 0.3 part of stearic acid; the upper stone-plastic plate layer and the lower stone-plastic plate layer have the same production formula, and each of the upper stone-plastic plate layer and the lower stone-plastic plate layer comprises the following raw materials in parts by mass: 25 parts of type 5 PVC resin powder; 40 to 55 parts of calcium powder; 5-20 parts of chopped glass fiber powder; 1-2 parts of a stabilizer; 0.1 to 0.3 part of paraffin; and 0.1 to 0.3 part of stearic acid. The chopped glass fiber powder is added, so that the internal and external friction force of a molten mass in the plastic extrusion process is improved, and the extrusion speed and productivity are improved.

Description

Technical Field

[0001] The invention belongs to the technical field of decorative plates, and in particular relates to a toughened and impact-resistant multi-layer composite decorative plate and a preparation method thereof. Background Art

[0002] The wood-plastic and stone-plastic decorative boards on the current market are mostly made of PVC, which is a new type of decorative material developed through high-quality and high-tech research. They are widely used because of their light weight, beautiful appearance, easy cutting, and convenient and fast construction. In order to cater to the market's choice of decorative boards with different patterns and models, the existing production process mainly manufactures a decorative base plate and then sets various types of decorative surface layers with different patterns on its surface. Among them, the decorative base plate is a solid sheet base with a high-density, high-fiber mesh structure formed by high-temperature extrusion, cooling and shaping of stone powder, wood fiber and plastic resin, which is mainly used in the field of base plates; and the decorative surface layer can be a decorative film composited with polyurethane cold glue or PUr hot melt glue, or a paint layer with UV varnish layer or EB coating.

[0003] Plastic products are produced in a high-energy-consuming process due to their high-temperature extrusion process. Improving the extrusion speed and thus the production capacity of decorative baseboards can effectively reduce energy consumption and save production costs. The toughness and impact resistance of decorative baseboards are also key factors in determining the quality of decorative boards. The toughness and impact resistance of existing wood-plastic and stone-plastic decorative boards still need to be improved. Therefore, in order to increase the market competitiveness of products, it is particularly important to further improve product quality from aspects such as improving the toughness and impact resistance of decorative baseboards. Summary of the invention

[0004] In view of the deficiencies in the prior art, the purpose of the present invention is to provide a toughened and impact-resistant multi-layer composite decorative board and a preparation method thereof, thereby solving the problems in the prior art.

[0005] The purpose of the present invention can be achieved through the following technical solutions:

[0006] A toughened and impact-resistant multi-layer composite decorative board, comprising: a foamed fiber board layer, an upper stone-plastic board layer and a lower stone-plastic board layer arranged on the upper and lower surfaces of the foamed fiber board layer, and a decorative surface layer arranged on the upper surface of the upper stone-plastic board layer;

[0007] The foamed fiberboard layer comprises the following raw materials in parts by weight:

[0008]

[0009] The production formula of the upper stone-plastic board layer and the lower stone-plastic board layer is the same, and both include the following raw materials in parts by weight:

[0010]

[0011] Furthermore, the toughened and impact-resistant multi-layer composite decorative board is characterized in that the foamed fiber board layer has a thickness of 4-20 mm, the upper stone-plastic board layer has a thickness of 0.15-2 mm, and the lower stone-plastic board layer has a thickness of 0.1-0.5 mm.

[0012] Furthermore, the calcium powder is one of heavy calcium carbonate and light calcium carbonate, or a combination of both.

[0013] Furthermore, the fiber diameter of the chopped glass fiber powder is 9-14 μm, and the average fiber length is 35-400 μm.

[0014] Furthermore, the stabilizer is a lead-free salt stabilizer compounded with stearate;

[0015] Preferably, the stabilizer is zinc stearate, magnesium stearate or calcium stearate.

[0016] Furthermore, the foaming agent is: one or a combination of sulfonylhydrazide acrylic polymer foaming agent or azodimethylamine foaming agent.

[0017] The melting point of the polyethylene wax is 105-115°C, and the melting point of the paraffin wax is 56-64°C.

[0018] Furthermore, the toughened impact-resistant multi-layer composite decorative board material is characterized in that the decorative surface layer is: a decorative film compounded on the upper surface of the upper stone-plastic board layer using polyurethane cold glue or PUr hot melt glue, or is: a paint layer cured on the upper surface of the upper stone-plastic board layer using UV curing or EB curing technology.

[0019] The above-mentioned method for preparing a toughened impact-resistant multi-layer composite decorative board comprises the following steps:

[0020] S1, preparing the raw materials of the foamed fiber board layer, mixing and stirring in a high-speed mixer to 120° C., and then putting into a mixer to cool to below 50° C. to obtain a pre-plasticized mixture of the foamed fiber board layer;

[0021] S2, preparing the raw materials of the upper stone-plastic board layer and the lower stone-plastic board layer, mixing and stirring the raw materials in a high-speed mixer until the temperature reaches 120° C., and then putting the raw materials into a mixer for cold mixing, stirring and cooling the raw materials to below 50° C. to obtain a pre-plasticized mixture of the upper stone-plastic board layer and the lower stone-plastic board layer;

[0022] S3, the pre-plasticized mixture of the foamed fiber board layer, the upper stone plastic board layer and the lower stone plastic board layer are respectively extruded into a forming co-extrusion extrusion die through the main machine and the co-extrusion auxiliary machine of the twin-screw co-extruder with set heating temperature, the pre-plasticized mixture of the foamed fiber board layer, the upper stone plastic board layer and the lower stone plastic board layer are heated and melted and respectively extended into layers through the flow channels in the forming extrusion die and converged and laminated before co-extrusion, and after cooling and shaping, a multi-layer composite bottom plate is obtained;

[0023] S4, adjusting the flow control bolts above the mold and the temperature of each heating zone of the mold to control the thickness of each layer of the multi-layer composite decorative base plate;

[0024] S5, forming a composite decorative surface layer on the surface of the upper stone-plastic board layer of the multi-layer composite base plate to obtain a toughened and impact-resistant multi-layer composite decorative board.

[0025] Beneficial effects of the present invention:

[0026] 1. Chopped glass fiber powder is a short fiber with smooth surface, high hardness and high tensile strength. The present invention can effectively improve the internal friction of the melt itself during the plastic extrusion process and the external friction between the melt and the metal surface of the extrusion machine by adding chopped glass fiber powder, that is, improve the internal and external lubrication of the melt, reduce the flow resistance of the plastic melt inside the production machine and between the extrusion die, thereby increasing the extrusion speed and improving the production capacity.

[0027] 2. The chopped glass fiber powder added in the present invention replaces part of the calcium powder content that plays a filling role in the resin of the foamed fiberboard layer and the upper and lower stone-plastic board layers. The chopped glass fiber powder is a short filament fiber with high hardness and excellent fiber tensile strength, which can overlap the network skeleton in the resin, effectively improving the toughness, impact resistance, wear resistance and surface scratch resistance of the decorative baseboard, and improving the quality of the product.

[0028] 3. The decorative base plate of the multi-layer composite decorative board of the present invention is sequentially provided with a foamed fiberboard layer and stone-plastic board layers on the upper and lower surfaces. The foamed fiberboard layer is filled with fine tiny bubbles inside, thereby reducing the overall weight of the decorative base plate and alleviating the labor intensity during transportation and construction. Secondly, the stone-plastic board layers arranged on the upper and lower surfaces avoid the foamed fiberboard layer being directly exposed to the outside. The stone-plastic material itself has a high hardness and good wear resistance, while the foamed fiberboard layer itself has a low hardness and poor impact resistance. The stone-plastic board layers arranged on the upper and lower surfaces also effectively avoid the decorative base plate from being damaged due to external impact or scratching. DETAILED DESCRIPTION

[0029] The following will be combined with the embodiments of the present invention to clearly and completely describe the technical solution of the present invention. 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.

[0030] The technical solution of the present invention is specifically described below by the following examples; wherein the manufacturers, brands and specifications of the raw materials of the following examples and comparative examples are shown in Table 1:

[0031] Table 1 Manufacturer, brand and specification of raw materials

[0032]

[0033] Example 1

[0034] In this embodiment, the weight percentages of raw materials for preparing the toughened impact-resistant multi-layer composite decorative board are shown in Table 2 below:

[0035] Table 2 Raw material components of Example 1 by weight

[0036]

[0037] In this embodiment, the process of producing 8mm thick multilayer composite bottom plate (1220mm wide, upper stone plastic layer thickness 0.8mm, lower stone plastic layer thickness 0.2mm, foamed fiber board layer 7.0mm) by using 80 / 65 twin-screw co-extruder (80 twin-screw extruder as co-extrusion main machine extruding foamed fiber board pre-plastic mixture, 65 twin-screw extruder as co-extrusion auxiliary machine extruding stone plastic board pre-plastic mixture) is further described in detail as a specific embodiment step of the present invention;

[0038] A method for preparing a toughened impact-resistant multi-layer composite decorative sheet comprises the following steps:

[0039] S1, prepare the raw materials of the foamed fiber board layer according to the components in Table 2, mix and stir in a high-speed mixer until the temperature reaches 120° C., then put into a mixer and cool to below 50° C. to obtain a pre-plasticized mixture of the foamed fiber board layer;

[0040] S2, preparing the raw materials of the upper stone-plastic board layer and the lower stone-plastic board layer, mixing and stirring the raw materials in a high-speed mixer until the temperature reaches 120° C., and then putting the raw materials into a mixer for cold mixing, stirring and cooling the raw materials to below 50° C. to obtain a pre-plasticized mixture of the upper stone-plastic board layer and the lower stone-plastic board layer;

[0041] S3, set the temperature of each heating zone of the co-extrusion die to about 175°C (fine-tuned according to flow distribution). The 80 main machine is used to produce the pre-plasticized mixture of the extruded foamed fiber board layer, and the temperatures of the 80 main machine barrel zones 1 to 4 are set to 160°C, 165°C, 174°C, and 175°C respectively, and the main machine speed is set to the speed when the rated output power of the main machine inverter is 70%, and the feeding motor speed is adjusted until the melt plasticization effect meets the use requirements; the 65 co-extruder is used to produce the extruded stone-plastic board layer, and the temperatures of the 65 co-extrusion auxiliary machine barrel zones 1 to 4 are set to 163°C, 168°C, 176°C, and 178°C respectively, and the 65 co-extrusion main machine speed is set to the speed when the rated output current of the main machine inverter is 70%, and the feeding motor speed is adjusted until the melt plasticization effect meets the use requirements; the pre-plasticized mixture melts of the foamed fiber board layer and the stone-plastic board layer are extruded into the forming co-extrusion extrusion mold, and then extended into layers through their respective flow channels in the mold and co-extruded after converging and laminating, and a multi-layer composite bottom plate is obtained after cooling and shaping;

[0042] S4, adjusting the flow control bolts above the mold and the temperature of each heating zone of the mold to control the thickness of each layer of the multi-layer composite decorative base plate;

[0043] S5, the decorative base plate that meets the requirements is produced and extruded, and then compounded with 14-filament PVC decorative film through PU hot melt adhesive, and finally a toughened and impact-resistant multi-layer composite decorative plate is obtained.

[0044] Example 2

[0045] In this embodiment, the weight percentages of raw materials for preparing toughened impact-resistant multi-layer composite decorative board are shown in Table 3 below:

[0046] Table 3 Raw material components of Example 2 by weight

[0047]

[0048] In this embodiment, the process of producing 8mm thick composite multi-layer bottom plate (1220mm wide, upper stone plastic layer thickness 0.8mm, lower stone plastic layer thickness 0.2mm, foamed fiberboard layer 7.0mm) by 80 / 65 twin-screw co-extruder is used as a specific embodiment step to further describe the present invention in detail.

[0049] The specific preparation and production process is the same as the steps in Comparative Example 1.

[0050] Example 3

[0051] In this embodiment, the mass fractions of raw materials for preparing the chopped glass fiber powder modified multi-layer composite decorative board are shown in Table 4 below:

[0052] Table 4 Raw material components of Example 3 by weight

[0053]

[0054]

[0055] In this embodiment, the process of producing 8mm thick composite multi-layer bottom plate (1220mm wide, upper stone plastic layer thickness 0.4mm, lower stone plastic layer thickness 0.2mm, foamed fiberboard layer 7.4mm) by 80 / 65 twin-screw co-extruder is used as a specific embodiment step to further describe the present invention in detail.

[0056] The specific preparation and production process is the same as the steps in Example 1.

[0057] Example 4

[0058] In this embodiment, the mass fractions of raw materials for preparing the chopped glass fiber powder modified multi-layer composite decorative board are shown in Table 5 below:

[0059] Table 5 Raw material components of Example 4 by weight

[0060]

[0061] In this embodiment, the process of producing 8mm thick composite multi-layer bottom plate (1220mm wide, upper stone plastic layer thickness 0.4mm, lower stone plastic layer thickness 0.2mm, foamed fiberboard layer 7.4mm) by 80 / 65 twin-screw co-extruder is used as a specific embodiment step to further describe the present invention in detail.

[0062] The specific preparation and production process is the same as the steps in Example 1.

[0063] Example 5

[0064] In this embodiment, the mass fractions of raw materials for preparing the chopped glass fiber powder modified multi-layer composite decorative board are shown in Table 6 below:

[0065] Table 6 Raw material components of Example 5 by weight

[0066]

[0067] In this embodiment, the process of producing 8mm thick composite multi-layer bottom plate (1220mm wide, upper stone plastic layer thickness 0.4mm, lower stone plastic layer thickness 0.2mm, foamed fiberboard layer 7.4mm) by 80 / 65 twin-screw co-extruder is used as a specific embodiment step to further describe the present invention in detail.

[0068] The specific preparation and production process is the same as the steps in Example 1.

[0069] Example 6

[0070] In this embodiment, the mass fractions of raw materials for preparing the chopped glass fiber powder modified multi-layer composite decorative board are shown in Table 7 below:

[0071] Table 7 Raw material components of Example 6 by weight

[0072]

[0073] In this embodiment, the process of producing 8mm thick composite multi-layer bottom plate (1220mm wide, upper stone plastic layer thickness 0.4mm, lower stone plastic layer thickness 0.2mm, foamed fiberboard layer 7.4mm) by 80 / 65 twin-screw co-extruder is used as a specific embodiment step to further describe the present invention in detail.

[0074] The specific preparation and production process is the same as the steps in Example 1.

[0075] Comparative Example 1

[0076] The only difference between Comparative Example 1 and Example 1 is that no chopped glass fiber powder is added to the raw materials of the foam fiber board layer, the upper stone-plastic board layer and the lower stone-plastic board layer of the comparative example, and the other production processes, equipment and parameters are the same as those of Example 1.

[0077] Table 8 Comparative Example 1 Raw material components by weight

[0078]

[0079] In this comparative example, the process of producing 8 mm thick composite multi-layer bottom plate (1220 mm wide, upper stone-plastic layer thickness 0.4 mm, lower stone-plastic layer thickness 0.2 mm, foamed fiberboard layer 7.4 mm) by 80 / 65 twin-screw co-extruder is used as a specific comparative example step to further describe the present invention in detail.

[0080] The specific preparation and production process is the same as the steps in Example 1.

[0081] Performance Testing

[0082] The performance requirements and test methods shall be in accordance with T-ZZB 1671-2020 "Bamboo and Wood Fiber Decorative Boards".

[0083] The performance data of the toughened impact-resistant multi-layer composite decorative panels prepared in Examples 1-6 and Comparative Example 1 are shown in Table 9.

[0084] Table 9 Performance statistics of multi-layer composite decorative panels prepared in Examples 1-6 and Comparative Example 1

[0085]

[0086]

[0087] 1. It can be seen from the test results in Table 9 that with the addition of chopped glass fiber powder in Examples 1-4 and Comparative Example 1, the production capacity of the decorative baseboard is significantly increased. The reason is that the chopped glass fiber powder added in the present invention is a short filament fiber with a smooth surface, high hardness and high tensile strength, which can effectively improve the internal friction of the melt itself during the plastic extrusion process and the external friction between the melt and the metal surface of the extrusion machine, that is, improve the internal and external lubrication of the melt, reduce the flow resistance of the plastic melt inside the production machine and between the extrusion die, thereby increasing the extrusion speed and increasing the production capacity;

[0088] 2. It can be seen from the test results in Table 9 that the chopped glass fiber powder added in Examples 1-4 and Comparative Example 1 replaces part of the calcium powder content that fills the foamed fiberboard layer and the upper and lower stone-plastic board layers. The chopped glass fiber powder is a short fiber with high hardness and excellent fiber tensile strength, which can be connected to form a network skeleton in the resin, effectively improving the hardness, bending resistance, toughness, impact resistance, wear resistance and surface scratch resistance of the decorative baseboard, thereby improving the quality of the product.

[0089] 3. It can be seen from the test results in Table 9 that the decorative base plate of the multi-layer composite decorative board of the present invention is provided with a foamed fiber board layer and stone-plastic board layers on the upper and lower surfaces in sequence, wherein the foamed fiber board layer is filled with fine micro bubbles, thereby effectively reducing the overall weight of the decorative base plate (reducing the density of the decorative board) and reducing the labor intensity during transportation and construction;

[0090] 4. From the comparison of the test results of Example 3, Example 5 and Example 6 in Table 9, it can be seen that changing the amount of relevant additives such as stabilizer, foaming agent, foaming regulator, polyethylene wax, paraffin, stearic acid, etc. in the formula composition will also change the production capacity and output of the decorative baseboard. Considering various production factors such as cost, Example 3 of the present invention is the best;

[0091] 5. The stone-plastic board layers arranged on the upper and lower surfaces of the decorative baseboard of the present invention avoid the foamed fiberboard layer being directly exposed to the outside. The stone-plastic material itself has high hardness and good wear resistance, while the foamed fiberboard layer itself has low hardness and poor impact resistance. The stone-plastic board layers arranged on the upper and lower surfaces also effectively avoid the decorative baseboard from being damaged due to external impact or scratching.

[0092] In the description of this specification, the description with reference to the terms "one embodiment", "example", "specific example", etc. means that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present invention. In this specification, the schematic representation of the above terms does not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described can be combined in any one or more embodiments or examples in a suitable manner.

[0093] The above shows and describes the basic principles, main features and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments, and the above embodiments and descriptions are only for explaining the principles of the present invention. Without departing from the spirit and scope of the present invention, the present invention may have various changes and improvements, and these changes and improvements all fall within the scope of the present invention to be protected.

Claims

1. A toughened and impact-resistant multi-layer composite decorative sheet, characterized in that: include: A foamed fiber board layer, an upper stone-plastic board layer and a lower stone-plastic board layer arranged on the upper and lower surfaces of the foamed fiber board layer, and a decorative surface layer arranged on the upper surface of the upper stone-plastic board layer; The foamed fiberboard layer comprises the following raw materials in parts by weight: The production formula of the upper stone-plastic board layer and the lower stone-plastic board layer is the same, and both include the following raw materials in parts by weight:

2. The toughened impact-resistant multi-layer composite decorative board according to claim 1, characterized in that: The foamed fiber board layer has a thickness of 4-20 mm, the upper stone-plastic board layer has a thickness of 0.15-2 mm, and the lower stone-plastic board layer has a thickness of 0.1-0.5 mm.

3. The toughened impact-resistant multi-layer composite decorative board according to claim 1, characterized in that: The calcium powder is one of heavy calcium carbonate and light calcium carbonate or a combination of both.

4. The toughened impact-resistant multi-layer composite decorative board according to claim 1, characterized in that: The fiber diameter of the chopped glass fiber powder is 9-14 μm, and the average fiber length is 35-400 μm.

5. The toughened impact-resistant multi-layer composite decorative board according to claim 1, characterized in that: The stabilizer is a lead-free salt stabilizer compounded with stearate.

6. The toughened impact-resistant multi-layer composite decorative board according to claim 5, characterized in that: The stabilizer is zinc stearate, magnesium stearate or calcium stearate.

7. The toughened impact-resistant multi-layer composite decorative board according to claim 1, characterized in that: The foaming agent is: one or a combination of sulfonylhydrazide acrylic polymer foaming agent or azodimethylamine foaming agent.

8. The toughened impact-resistant multi-layer composite decorative board according to claim 1, characterized in that: The melting point of the polyethylene wax is 105-115°C, and the melting point of the paraffin wax is 56-64°C.

9. The toughened impact-resistant multi-layer composite decorative board according to claim 1, characterized in that: The decorative surface layer is a decorative film compounded on the upper surface of the upper stone-plastic board layer using polyurethane cold glue or PUr hot melt glue, or a paint layer cured on the upper surface of the upper stone-plastic board layer using UV curing or EB curing technology.

10. A method for preparing a toughened impact-resistant multi-layer composite decorative sheet according to any one of claims 1 to 9, characterized in that: The following steps are involved: S1, preparing the raw materials of the foamed fiber board layer, mixing and stirring in a high-speed mixer to 120° C., and then putting into a mixer to cool to below 50° C. to obtain a pre-plasticized mixture of the foamed fiber board layer; S2, preparing the raw materials of the upper stone-plastic board layer and the lower stone-plastic board layer, mixing and stirring the raw materials in a high-speed mixer until the temperature reaches 120° C., and then putting the raw materials into a mixer for cold mixing, stirring and cooling the raw materials to below 50° C. to obtain a pre-plasticized mixture of the upper stone-plastic board layer and the lower stone-plastic board layer; S3, the pre-plasticized mixture of the foamed fiber board layer, the upper stone plastic board layer and the lower stone plastic board layer are extruded into a forming co-extrusion extrusion die through the main machine and the co-extrusion auxiliary machine of the twin-screw co-extruder with set heating temperature, the pre-plasticized mixture of the foamed fiber board layer, the upper stone plastic board layer and the lower stone plastic board layer are heated and melted and respectively extended into layers through the flow channels in the forming extrusion die and converged and laminated before co-extrusion, and after cooling and shaping, a multi-layer composite bottom plate is obtained; S4, adjusting the flow control bolts above the mold and the temperature of each heating zone of the mold to control the thickness of each layer of the multi-layer composite decorative base plate; S5, forming a composite decorative surface layer on the surface of the upper stone-plastic board layer of the multi-layer composite base plate to obtain a toughened and impact-resistant multi-layer composite decorative board.

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