EB-cured polypropylene film veneer composite wood-plastic floor and production process thereof

Abstract

The invention belongs to the technical field of ground paving materials, and relates to an EB-cured polypropylene film veneer composite wood-plastic floor which sequentially comprises a surface decoration layer, a gluing layer and a wood-plastic base material main body layer from top to bottom, the thickness of the surface decoration layer of the floor is 0.27 + / -0.05 mm, and the surface decoration layer is a single-layer or four-layer EB-cured polypropylene film; the thickness of the wood-plastic composite base material main body layer is 10-18mm, and the wood-plastic composite base material main body layer is a wood-plastic material formed by mixing polyolefins and more than 50% of waste plant fibers in a thermoplastic manner; the invention further discloses a production process of the floor. The method is simple in process, more environmentally friendly and relatively low in comprehensive cost. The surface layer and the base material are glued and pressed, the bonding speed is high during pressing, flow line production can be achieved, substances harmful to the human body and the environment cannot be released in the bonding process and after bonding, and the prepared solid wood veneer decorative plate inherits the characteristics of elegance and nature of a solid wood plate and has good waterproofness, water resistance, stability, decoration and durability.

Description

Technical Field

[0001] The invention belongs to the technical field of floor paving materials, relates to solid wood composite flooring, and in particular to an EB-cured polypropylene film-faced composite wood-plastic flooring and a production process thereof. Background Art

[0002] Multi-layer solid wood composite flooring is a popular home decoration in the furniture and building materials industry. However, with the shortage of forest resources, natural solid wood surfaces with beautiful patterns are becoming increasingly scarce. How to effectively improve the comprehensive utilization rate of wood resources and alleviate the current tight supply of wood resources is a technical issue that needs to be studied and solved urgently. Wood-plastic composite materials have secondary processing properties, and the products made from them have beautiful appearances. They are one of the ideal substitutes for wood. They are also environmentally friendly materials that can be recycled and reused. The raw materials are cheap and abundant. They have good benefits in reducing environmental pollution, protecting forest resources, and promoting economic development, and have attracted the attention of many researchers.

[0003] Chinese patent CN112575983A discloses a free-to-assemble wood-plastic wallboard and its production process. The wood-plastic substrate body is coated with a PVC / EB film, and its upper surface is flat and the lower surface is wavy. The disclosed free-to-assemble wood-plastic wallboard uses wood-plastic as the substrate and is coated with a PVC / EB decorative transfer film. The overall surface is flat, and the left and right sides and the equally divided parts are solid structures, and the remaining parts are hollow solid structures. The post-molding processability is strong and the ductility is high. It is an environmentally friendly, practical and aesthetically pleasing wallboard product, and the production process is simple. Chinese patent CN207808670U discloses an electron-cured film multi-layer composite floor, which includes a UV paint film, an electron-cured film and a multi-layer substrate layer from top to bottom, wherein the multi-layer substrate layer is a plywood formed by criss-crossing and laminating fast-growing veneers, and the upper surface of the plywood is bonded with a polyvinyl alcohol adhesive to bond the electron-cured film. Chinese patent CN109537847A discloses an EB-cured polypropylene film-faced multi-layer composite floor and its production process, and discloses a multi-layer solid wood composite floor prepared from a multi-layer plywood substrate with an EB film-faced multi-layer. The multi-layer plywood substrate is coated with an EB-cured polypropylene film, and the tongue and groove are flat. Summary of the invention

[0004] In view of the deficiencies in the above-mentioned prior art, the purpose of the present invention is to disclose a composite wood-plastic floor with EB-cured polypropylene film facing. The composite board formed by the wood-plastic substrate and the EB-cured polypropylene film can inherit the elegant and natural characteristics of the solid wood board. From the perspective of protecting forest resources, it is a substitute product for the solid wood board and can effectively reduce the consumption of wood. It has good waterproofness, water resistance, stability, decorativeness, durability, etc.

[0005] Technical Solution

[0006] The invention discloses an EB-cured polypropylene film-faced composite wood-plastic floor, which comprises, from top to bottom, a surface decorative layer, a coating layer and a main layer of a wood-plastic base material, wherein the surface decorative layer of the floor has a thickness of 0.27±0.05 mm and is a single-layer or four-layer EB-cured polypropylene film; the main layer of the wood-plastic composite base material has a thickness of 10 to 18 mm and is a wood-plastic material formed by thermoplastic mixing of polyolefins and more than 50% of waste plant fibers.

[0007] In a preferred disclosed example of the present invention, the EB-cured polypropylene film is a single layer, the surface of which has a wood-like texture pattern, and the back has paint or a special plane or antique effect pattern, or the surface of which has a paint or a special plane or antique effect pattern, and the back has a wood-like texture pattern; because the polypropylene film is transparent, the wood texture and the paint effect pattern overlap.

[0008] In the preferred disclosed example of the present invention, the EB-cured polypropylene film has a total of four layers, among which, from top to bottom, there are the surface layer, which is a tough coating, a scratch-resistant, sunlight-resistant protective layer; the second layer, a transparent concave-convex layer with the high and low texture of the wood surface; the third layer, a printed layer with clear wood grain of the tree species; and the bottom layer, a base layer for coloring and fixing.

[0009] In the preferred disclosed example of the present invention, the surface decorative layer and the main layer of the wood-plastic substrate are bonded by a polyurethane resin adhesive layer, the thickness of the adhesive layer is 0.1-0.2 mm, and it is a polyurethane resin hot melt adhesive, which overcomes the problem that the film is prone to surface defects on the rough wood surface, and a lower coating amount can achieve better bonding strength.

[0010] In a preferred disclosed example of the present invention, the polyolefin in the main layer of the wood-plastic composite substrate is polyethylene, polypropylene or polyvinyl chloride.

[0011] In a preferred disclosed example of the present invention, the waste plant fibers in the main layer of the wood-plastic composite substrate are wood powder, rice husks, straw, etc.

[0012] In a preferred disclosed example of the present invention, the EB-cured polypropylene film-faced composite wood-plastic floor has a tongue-and-groove structure at the long end edge for a lock connection.

[0013] The main body of the wood-plastic substrate has good processing performance, good strength performance, water resistance, corrosion resistance, long service life, excellent adjustable performance, and UV light stability; the biggest advantage is that it turns waste into treasure and can be 100% recycled and reproduced. It can be decomposed and will not cause "white pollution". It is a truly green and environmentally friendly product. The raw materials are widely available and can be made into any shape and size according to needs.

[0014] Another object of the present invention is to disclose a production process of the above-mentioned EB-cured polypropylene film-faced composite wood-plastic floor, comprising the following steps:

[0015] (1) Preparation of the main body of the wood-plastic substrate: the raw materials are mixed evenly according to the ratio and sent into the extruder, the temperature of the heating zone is 140°C to 185°C, and the heating time is 30 to 35 minutes to soften the raw materials, glue them and shape them into the extruded sheet to obtain the substrate;

[0016] (2) Lamination: After the surface of the substrate is sanded and dusted, the surface is coated with polyurethane resin hot melt adhesive with a coating amount of 45 to 65 g / m 2 ; Set the lamination distance, and laminate the EB-cured polypropylene film and the substrate at one time;

[0017] (3) Balanced curing: After lamination, the boards are quickly cut, stacked face to face, and placed in a balance room for curing for ≥ 7 days;

[0018] (4) Cutting: Cut the balanced and cured substrate into strips, and sand the back to determine the thickness to form floor strips;

[0019] (5) Forming: tongue and groove the floor strips;

[0020] (6) Chamfering paint: spray chamfering paint on the chamfered position of the floor to adapt to the color of the board surface and make it coordinated and unified;

[0021] (7) Sealing wax: Spray plant series silent wax on the floor lock groove. The coating amount is adjusted according to the lock type, about 20-30g / m 2 ;

[0022] (8) Finished product packaging: After passing the quality QC inspection, the product will be directly packaged.

[0023] In a preferred disclosed example of the present invention, the raw material ratio in step (1) is 52-70% by weight of polyolefins, and the rest is waste plant fibers.

[0024] In a preferred disclosed example of the present invention, the polyolefin in step (1) is polyethylene, polypropylene or polyvinyl chloride, etc., preferably polypropylene; the waste plant fiber is wood powder, rice husk, straw, etc., preferably wood powder.

[0025] Beneficial Effects

[0026] The invention discloses an EB-cured polypropylene film-faced composite wood-plastic floor and a production process thereof. A polypropylene film having wood texture, antique effect and paint treatment effect cured by an Electron Beam process is attached to the surface of the wood-plastic floor to prepare a special structure of an EB-cured polypropylene film-faced lock-and-lock multi-layer composite floor. The composite floor can inherit the elegant and natural characteristics of solid wood boards. From the perspective of protecting forest resources, it is a substitute product for solid wood boards, which can effectively reduce the consumption of wood, solve the tense situation of forest resource shortage and thus protect natural resources. Compared with the existing composite floor and the existing technology, the process is simple, more environmentally friendly and the comprehensive cost is relatively low. The invention adopts a polyurethane hot melt adhesive bonding process to glue and press the surface layer and the substrate. The bonding speed is fast during pressing, and assembly line production can be realized. No substances harmful to the human body and the environment will be released during and after bonding, so that the prepared new solid wood veneer decorative board inherits the elegant and natural characteristics of solid wood boards, and has good waterproofness, water resistance, stability, decorativeness and durability. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 . A schematic diagram of the structure of a composite wood-plastic flooring with an EB-cured polypropylene film finish, wherein: 1. a surface decorative layer, 2. a coating layer, 3. a main body layer of a wood-plastic substrate. DETAILED DESCRIPTION

[0028] The present invention is described in detail below in conjunction with the embodiments so that those skilled in the art can better understand the present invention, but the present invention is not limited to the following embodiments.

[0029] Example 1

[0030] The invention discloses an EB-cured polypropylene film-faced composite wood-plastic floor, which comprises, from top to bottom, a surface decorative layer 1, a glue coating layer 2 and a wood-plastic base material main layer 3. The surface decorative layer 1 of the floor has a thickness of 0.27±0.05 mm and is a single-layer EB-cured polypropylene film, with a wood-like texture pattern on the surface and a pattern with paint or a special plane or antique effect on the back. The wood texture and the paint effect pattern are overlapped because the polypropylene film is transparent. The wood-plastic composite base material main layer 3 has a thickness of 10 to 18 mm and is a wood-plastic material made by thermoplastic mixing of polyolefins and more than 50% of waste plant fibers.

[0031] Example 2

[0032] The invention discloses an EB-cured polypropylene film-faced composite wood-plastic floor, which comprises, from top to bottom, a surface decorative layer 1, a glue coating layer 2 and a wood-plastic base material main layer 3, wherein the surface decorative layer 1 of the floor has a thickness of 0.27±0.05 mm and is a four-layer EB-cured polypropylene film, which comprises, from top to bottom, a surface layer, which is a tough coating, a scratch-proof and sunlight-resistant protective layer; a second layer, which is a transparent concave-convex layer with a sense of high and low texture of the wood surface; a third layer, which is a printing layer with clear wood grain of the tree species; and a bottom layer, which is a base layer for coloring and fixing; the wood-plastic composite base material main layer 3 has a thickness of 10 to 18 mm and is a wood-plastic material made by thermoplastic mixing of polyolefins and more than 50% of waste plant fibers.

[0033] Example 3

[0034] The invention discloses an EB-cured polypropylene film-faced composite wood-plastic floor, which comprises a surface decorative layer 1, a coating layer 2 and a wood-plastic substrate main body layer 3 from top to bottom, wherein the surface decorative layer 1 of the floor is 0.27±0.05 mm thick and is a single-layer EB-cured polypropylene film, the surface of which has a paint or special plane or antique effect pattern, and the back has a wood-like texture pattern; the wood texture and the paint effect pattern are superimposed because the polypropylene film is transparent; the wood-plastic composite substrate main body layer 3 is 10-18 mm thick and is a wood-plastic material made by thermoplastic mixing of polyolefins and more than 50% of waste plant fibers; the surface decorative layer 1 and the wood-plastic substrate main body layer 3 are bonded by a polyurethane resin adhesive layer, the coating layer 2 is 0.1-0.2 mm thick and is a polyurethane resin hot melt adhesive, which overcomes the problem that the film is prone to surface defects on a rough wood surface, and a lower coating amount can achieve better bonding strength.

[0035] Example 4

[0036] The invention discloses an EB-cured polypropylene film-faced composite wood-plastic floor, which comprises, from top to bottom, a surface decorative layer 1, a coating layer 2 and a wood-plastic substrate main body layer 3, wherein the surface decorative layer 1 of the floor has a thickness of 0.27±0.05 mm and is a four-layer EB-cured polypropylene film, which comprises, from top to bottom, a surface layer, which is a hard coating, a scratch-resistant and sunlight-resistant protective layer; a second layer, which is a transparent concave-convex layer with a sense of high and low texture on the surface of wood; a third layer, which is a printing layer with clear wood grain of tree species; and a bottom layer, which is a base layer for coloring and fixing; the wood-plastic composite substrate main body layer 3 has a thickness of 10 to 18 mm and is a wood-plastic material made by thermoplastic mixing of polyolefins and more than 50% of waste plant fibers; the surface decorative layer 1 and the wood-plastic substrate main body layer 3 are bonded by a polyurethane resin adhesive layer, and the coating layer 2 has a thickness of 0.1 to 0.2 mm and is a polyurethane resin hot melt adhesive, which overcomes the problem that the film is prone to surface defects on the rough wood surface, and a lower coating amount can achieve better bonding strength.

[0037] Example 5

[0038] An EB-cured polypropylene film-faced composite wood-plastic floor comprises, from top to bottom, a surface decorative layer 1, a coating layer 2 and a wood-plastic substrate main body layer 3, wherein the surface decorative layer 1 of the floor is 0.27±0.05 mm thick and is a single-layer EB-cured polypropylene film, the surface of which has a paint or special flat or antique effect pattern, and the back has a wood-like texture pattern; the wood texture and the paint effect pattern are superimposed because the polypropylene film is transparent; the wood-plastic composite substrate main body layer 3 is 10 to 18 mm thick and is a composite of polyolefins and more than 5 The surface decorative layer 1 and the main body layer 3 of the wood-plastic composite substrate are bonded by a polyurethane resin adhesive layer. The adhesive layer 2 has a thickness of 0.1 to 0.2 mm and is a polyurethane resin hot melt adhesive. This overcomes the problem that the film is prone to surface defects on the rough wood surface, and a lower coating amount can achieve better bonding strength. The polyolefins in the main body layer 3 of the wood-plastic composite substrate are polyethylene, polypropylene or polyvinyl chloride, etc., and the waste plant fibers in the main body layer 3 of the wood-plastic composite substrate are wood powder, rice husks, and straw.

[0039] Example 6

[0040] A composite wood-plastic floor with EB-cured polypropylene film facing, which comprises, from top to bottom, a surface decorative layer 1, a coating layer 2 and a wood-plastic substrate main layer 3, wherein the surface decorative layer 1 of the floor has a thickness of 0.27±0.05 mm and is a four-layer EB-cured polypropylene film, which comprises, from top to bottom, a surface layer, which is a hard coating, a scratch-resistant, sunlight-resistant protective layer; a second layer, a transparent concave-convex layer with a sense of high and low texture of the wood surface; a third layer, a printing layer with clear wood grain of the tree species; a bottom layer, which is a base layer for coloring and fixing; the thickness of the wood-plastic composite substrate main layer 3 is 10 to 18 mm, is a wood-plastic material made by thermoplastic mixing of polyolefins and more than 50% of waste plant fibers; the surface decorative layer 1 and the wood-plastic substrate main layer 3 are bonded by a polyurethane resin adhesive layer, the coating layer 2 has a thickness of 0.1-0.2 mm, and is a polyurethane resin hot melt adhesive, which overcomes the problem that the film is prone to surface defects on the rough wood surface, and a lower coating amount can achieve better bonding strength; the polyolefins in the main layer 3 of the wood-plastic composite substrate are polyethylene, polypropylene or polyvinyl chloride, etc., and the waste plant fibers in the main layer 3 of the wood-plastic composite substrate are wood powder, rice husks, straw, etc.

[0041] Example 7

[0042] A production process for preparing the above-mentioned EB-cured polypropylene film-faced composite wood-plastic floor comprises the following steps:

[0043] (1) Preparation of the main body of the wood-plastic substrate: the raw materials are mixed uniformly according to the ratio and fed into the extruder, the temperature of the heating zone is 140°C to 185°C, and the heating time is 30 to 35 minutes to soften the raw materials, glue them and shape them into the shape of the extruded board. The raw material ratio is 52% of the mass of polyolefins, and the rest is waste plant fibers. The polyolefin is polypropylene, and the waste plant fibers are wood powder;

[0044] (2) Lamination: After sanding and dust removal, apply polyurethane resin hot melt adhesive on the surface of the substrate with a coating amount of 45-65g / m 2 ; Set the pasting interval, and paste the EB-cured polypropylene film with natural wood texture, antique effect, and paint treatment effect on the substrate at one time;

[0045] (3) Balanced curing: Cut the laminated boards quickly, stack them face to face, and place them in a balance room for curing for ≥ 7 days;

[0046] (4) Cutting: Cut the balanced and cured substrate into strips, and sand the back to determine the thickness to form floor strips;

[0047] (5) Forming: tongue and groove the floor strips;

[0048] (6) Chamfering paint: spray chamfering paint on the chamfered position of the floor to adapt to the color of the board surface and make it coordinated and unified;

[0049] (7) Sealing wax: Spray plant series silent wax on the floor lock groove. The coating amount is adjusted according to the lock type, about 20-30g / m 2 ;

[0050] (8) Finished product packaging: After passing the quality QC inspection, the product will be directly packaged.

[0051] Example 8

[0052] A production process for preparing the above-mentioned EB-cured polypropylene film-faced composite wood-plastic floor comprises the following steps:

[0053] (1) Preparation of the main body of the wood-plastic substrate: the raw materials are mixed uniformly according to the ratio and fed into the extruder, the temperature of the heating zone is 140°C to 185°C, and the heating time is 30 to 35 minutes to soften the raw materials, glue them and shape them into the extruded sheet shape, the raw material ratio is 70% by weight of polyolefins, and the rest is waste plant fibers, the polyolefin is polyethylene, and the waste plant fibers are rice husks;

[0054] (2) Lamination: After the surface of the substrate is sanded and dusted, a polyurethane resin hot melt adhesive is applied on the surface with a coating amount of 45 to 65 g / m 2 ; Set the pasting interval, and paste the EB-cured polypropylene film with natural wood texture, antique effect, and paint treatment effect on the substrate at one time;

[0055] (3) Balanced curing: Cut the laminated boards quickly, stack them face to face, and place them in a balance room for curing for ≥ 7 days;

[0056] (4) Cutting: Cut the balanced and cured substrate into strips, and sand the back to determine the thickness to form floor strips;

[0057] (5) Forming: tongue and groove the floor strips;

[0058] (6) Chamfering paint: spray chamfering paint on the chamfered position of the floor to adapt to the color of the board surface and make it coordinated and unified;

[0059] (7) Sealing wax: Spray plant series silent wax on the floor lock groove. The coating amount is adjusted according to the lock type, about 20-30g / m 2 ;

[0060] (8) Finished product packaging: After passing the quality QC inspection, the product will be directly packaged.

[0061] The above descriptions are merely embodiments of the present invention and are not intended to limit the patent scope of the present invention. Any equivalent structure or equivalent process transformation made using the specification of the present invention, or directly or indirectly applied in other related technical fields, are also included in the patent protection scope of the present invention.

Claims

1. An EB-cured polypropylene film-faced composite wood-plastic floor, comprising, from top to bottom, a surface decorative layer (1), a rubber coating layer (2) and a wood-plastic substrate main layer (3), characterized in that: The surface decorative layer (1) of the floor has a thickness of 0.27±0.05 mm and is a single-layer or four-layer EB-cured polypropylene film; the main body layer (3) of the wood-plastic composite substrate has a thickness of 10 to 18 mm and is a wood-plastic material made by thermoplastically mixing polyolefins with more than 50% of waste plant fibers.

2. The EB-cured polypropylene film-faced composite wood-plastic flooring according to claim 1, characterized in that: The EB-cured polypropylene film is a single layer, with a wood-like texture pattern on its surface and a pattern of paint or special plane or antique effect on its back; or, with a paint or special plane or antique effect pattern on its surface and a wood-like texture pattern on its back; the wood texture and the paint effect pattern are superimposed because the polypropylene film is transparent.

3. The EB-cured polypropylene film-faced composite wood-plastic flooring according to claim 1, characterized in that: The EB-cured polypropylene film has four layers, from top to bottom, the surface layer is a tough coating, a scratch-resistant and sunlight-resistant protective layer; The second layer is a transparent concave and convex layer with the high and low texture of the wood surface; the third layer is a printed layer with clear wood grain of the tree species; The bottom layer is the base layer used for coloring and fixing.

4. The EB-cured polypropylene film-faced composite wood-plastic flooring according to claim 1, characterized in that: The surface decorative layer (1) and the wood-plastic base material main body layer (3) are bonded together via a polyurethane resin adhesive layer; the adhesive layer (2) has a thickness of 0.1 to 0.2 mm and is a polyurethane resin hot melt adhesive.

5. The EB-cured polypropylene film-faced composite wood-plastic flooring according to claim 1, characterized in that: The polyolefin in the main body layer (3) of the wood-plastic composite substrate is polyethylene, polypropylene or polyvinyl chloride.

6. The EB-cured polypropylene film-faced composite wood-plastic flooring according to claim 1, characterized in that: The waste plant fibers in the main layer (3) of the wood-plastic composite substrate are wood powder, rice husks, and straw.

7. The EB-cured polypropylene film-faced composite wood-plastic flooring according to claim 1, characterized in that: The long end edge of the floor is tongue-and-groove, and the mortise and tenon structure is lock-connected.

8. A process for producing the EB-cured polypropylene film-faced composite wood plastic flooring as claimed in any one of claims 1 to 7, characterized in that: The steps include: (1) The raw materials are mixed evenly according to the ratio and fed into the extruder. The temperature of the heating zone is 140℃~185℃. The heating time is 30~35min to soften the raw materials, glue and shape the extruded sheet to obtain the substrate; (2) After the surface of the substrate is sanded and dusted, the surface is coated with polyurethane resin hot melt adhesive with a coating amount of 45 to 65 g / m 2 ; Set the lamination distance, and laminate the EB-cured polypropylene film and the substrate at one time; (3) The laminated boards are cut quickly, stacked face to face, and placed in a balance room for curing for ≥ 7 days; (4) After balanced curing, the substrate is cut into strips, and the back is sanded to determine the thickness to form floor strips; (5) Forming: tongue and groove the floor strips; (6) Spray chamfer paint on the chamfered corners of the floor to match the color of the board surface and make it coordinated and unified; (7) Spray the plant series silent wax on the floor lock groove. The coating amount is adjusted according to the lock type, about 20-30g / m 2 ; (8) After passing the quality control test, the product will be directly packaged.

9. The production process of EB-cured polypropylene film-faced composite wood-plastic flooring according to claim 8, characterized in that: The raw material ratio in step (1) is 52-70% by weight of polyolefins, and the rest is waste plant fibers.

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