Wood stone floor and preparation method thereof

Abstract

The invention discloses a wood-stone floor and a preparation method thereof, the wood-stone floor comprises a surface layer and a base material layer which are sequentially arranged from top to bottom, and the surface layer comprises a wear-resistant layer and a balance layer which are sequentially arranged from top to bottom. The preparation raw materials of the base material layer take wood fibers and stone powder as cores, and have the advantages of light weight of wood and stability of stone; the decorative paper impregnated with melamine resin is molded on the surface of the base material layer, so that a low-cost and high-simulation wood grain / stone grain effect can be realized, additional coating is not needed, and the decorative paper is environment-friendly and durable; the bending strength of the wood-stone floor is larger than or equal to 30 MPa, the formaldehyde emission is smaller than or equal to 0.025 mg / m < 3 >, the ENF-grade standard is met, the wood-stone floor is more environmentally friendly, the surface wear-resisting revolution is larger than or equal to 9000 revolutions, the AC4 commercial grade is met, the 24-hour soaking water absorption thickness swelling rate is smaller than or equal to 8%, the wood-stone floor is superior to a common laminate floor, the wear resistance, moisture resistance, flame retardance and impact resistance of the floor are remarkably improved, the weight is light, the transportation cost is greatly reduced, and the wood-stone floor is suitable for large-scale popularization and application. The method is suitable for industrial popularization and application.

Description

Technical Field

[0001] The present invention belongs to the technical field of floors, and particularly relates to a wood-stone floor and a preparation method thereof. Background Art

[0002] The current mainstream floor covering materials mainly include the following categories: solid wood floors, natural stone floors, composite floors, wood-plastic / stone-plastic floors, etc. There are many types of floors, each with its own advantages and disadvantages. Traditional solid wood floors have a risk of deformation due to a relatively high moisture absorption expansion coefficient. Natural stone floors are limited by the problems of excessive self-weight and high processing and transportation costs. Ordinary composite floors such as laminate floors are mostly high-density fiberboards, which have poor water resistance, and the water absorption thickness swelling rate generally exceeds 10%, and the risk of formaldehyde release is high, unable to meet the requirements of green environmental protection. Wood-plastic or stone-plastic floors (WPC / SPC) have a plastic matrix, insufficient environmental protection and poor thermal stability.

[0003] Based on this, the present invention discloses a wood-stone floor and a preparation method thereof. Summary of the Invention

[0004] In order to solve the technical problems existing in the prior art, the purpose of the present invention is to provide a wood-stone floor and a preparation method thereof.

[0005] In order to achieve the above object and reach the above technical effect, the technical solution adopted by the present invention is as follows:

[0006] A wood-stone floor includes a surface layer and a base material layer arranged in sequence from top to bottom. The surface layer includes a wear-resistant layer and a balance layer arranged in sequence from top to bottom. The preparation raw materials of the base material layer include wood fiber, stone powder, adhesive, magnesium hydroxide, sodium hydroxide, and nano-titanium dioxide. The formaldehyde release amount of the wood-stone floor ≤ 0.025mg / m 3 .

[0007] Further, the preparation raw materials of the base material layer include the following components in parts by weight:

[0008] 40 - 70 parts of wood fiber

[0009] 20 - 50 parts of stone powder

[0010] 5 - 15 parts of adhesive

[0011] 5 - 20 parts of magnesium hydroxide

[0012] 2 - 10 parts of sodium hydroxide

[0013] 1 - 10 parts of nano-titanium dioxide.

[0014] Further, the preparation raw materials of the base material layer further include 5 - 13 parts of a flame retardant, and the oxygen index of the wood-stone floor ≥ 30.

[0015] Furthermore, the particle size of the stone powder is ≤ 100 mesh.

[0016] Furthermore, the adhesive is an environment-friendly melamine-modified urea adhesive or an isocyanate adhesive or a compound prepared by mixing pregelatinized starch and styrene-acrylic emulsion in a weight ratio of 2 - 4:1 - 3.

[0017] Furthermore, the density of the base material layer is ≥ 0.7 g / cm3, and the thickness is 6 - 12 mm.

[0018] Furthermore, a tenon - mortise lock is provided on the side of the base material layer, which is convenient for splicing and installation.

[0019] Furthermore, the wear-resistant layer is a decorative paper impregnated with melamine resin, and the thickness is 0.1 - 0.2 mm.

[0020] Furthermore, the balance layer is a decorative paper impregnated with melamine resin or non-woven fabric, and the thickness is 0.1 - 0.2 mm.

[0021] The present invention also discloses a preparation method of the wood - stone floor, which comprises the following steps:

[0022] 1) Preparation of the base material layer

[0023] By weight, 40 - 70 parts of wood fiber, 20 - 50 parts of stone powder, 2 - 10 parts of adhesive, 5 - 20 parts of magnesium hydroxide, 2 - 10 parts of sodium hydroxide, and 1 - 10 parts of nano - titanium dioxide are stirred and mixed evenly. Then, 5 - 13 parts of flame retardant and the remaining adhesive are added, and stirring and mixing are continued evenly. Then, it is paved and formed, and hot - pressed at 170 - 240 °C and 15 - 40 MPa for 1 - 4 min; after cooling, it is cut into slab blanks to obtain the required base material layer;

[0024] 2) Cover the upper surface of the base material layer with a decorative paper impregnated with melamine resin, and the impregnation amount of melamine resin is 100 - 200 g / m 2 , cover the lower surface of the base material layer with the balance layer, and mold - press at 170 - 220 °C and 8 - 18 MPa for 20 - 60 s to cure the melamine resin and bond it with the base material layer.

[0025] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0026] 1) The present invention discloses a wood - stone floor and its preparation method. The raw materials for preparing the base material layer are centered on wood fiber and stone powder, which have the advantages of both the lightness of wood and the stability of stone. Moreover, through the synergistic effect of wood fiber and stone powder, the problem of single performance of traditional materials is solved;

[0027] 2) The present invention discloses a wood-stone floor and its preparation method. The decorative paper impregnated with melamine resin is molded on the surface of the base material layer, which can achieve a low-cost and high-fidelity wood grain / stone grain effect without additional painting, and is suitable for home and commercial scenarios, with both environmental protection and durability.

[0028] 3) The present invention discloses a wood-stone floor and its preparation method. The flexural strength of the wood-stone floor is ≥30 MPa, and the formaldehyde release amount is ≤0.025 mg / m 3 , meeting the ENF-level standard, being more environmentally friendly. The surface wear resistance revolution number is ≥9000 revolutions, meeting the AC4 commercial grade. The thickness swelling rate of water absorption after 24-hour immersion is ≤8%, which is superior to ordinary laminate floors, and the wear resistance, moisture resistance, flame retardancy, and impact resistance of the floor are significantly improved. Moreover, it is lightweight, and the transportation cost is greatly reduced, making it suitable for industrialized popularization and use. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Figure 1 It is a schematic structural diagram of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0030] The present invention will be elaborated in detail below so that the advantages and features of the present invention can be more easily understood by those skilled in the art, thereby making a clearer and more definite definition of the protection scope of the present invention.

[0031] The following gives a brief overview of one or more aspects to provide a basic understanding of these aspects. This overview is not an exhaustive survey of all contemplated aspects, and is neither intended to identify the key or decisive elements of all aspects nor to define the scope of any or all aspects. Its sole purpose is to present some concepts of one or more aspects in a simplified form as a prelude to the more detailed description that follows.

[0032] As Figure 1 shown, a wood-stone floor includes a surface layer 1 and a base material layer 2 arranged in sequence from top to bottom. The surface layer 1 includes a wear-resistant layer 3 and a balance layer 4 arranged in sequence from top to bottom. The preparation raw materials of the base material layer 2 include wood fiber, stone powder, adhesive, magnesium hydroxide, sodium hydroxide, and nano-titanium dioxide. The flexural strength of the wood-stone floor is ≥30 MPa, and the formaldehyde release amount is ≤0.025 mg / m 3 , meeting the ENF-level standard, the surface wear resistance revolution number is ≥9000 revolutions, meeting the AC4 commercial grade, and the thickness swelling rate of water absorption is ≤8% (24-hour immersion), which is superior to ordinary laminate floors (≤15%).

[0033] The preparation raw materials of the base material layer include the following components in parts by weight:

[0034] 40 - 70 parts of wood fiber

[0035] 20 - 50 parts of stone powder

[0036] 5 - 15 parts of adhesive

[0037] 5 - 20 parts of magnesium hydroxide

[0038] 2 - 10 parts of sodium hydroxide

[0039] 1 - 10 parts of nano - titanium dioxide.

[0040] According to the actual flame - retardant requirements of the present invention, 5 - 13 parts of flame retardant (such as aluminum hydroxide, etc.) can be added to the preparation raw materials of the substrate layer, so that the oxygen index of the wood - stone floor is ≥30, reaching B1 - level flame retardancy.

[0041] In some embodiments, the particle size of the stone powder is ≤100 mesh.

[0042] In some embodiments, the adhesive is environmentally friendly melamine - modified urea glue or isocyanate - based adhesive or a compound of pre - gelatinized starch and styrene - acrylic emulsion in a weight ratio of 2 - 4:1 - 3.

[0043] In some embodiments, a tenon - groove lock is provided on the side of the substrate layer, which is convenient for splicing and installation.

[0044] In some embodiments, the density of the substrate layer is ≥0.7 g / cm3, and the thickness is 6 - 12 mm.

[0045] In some embodiments, the wear - resistant layer is a decorative paper impregnated with melamine resin, and the thickness is 0.1 - 0.2 mm.

[0046] In some embodiments, the balance layer is a decorative paper impregnated with melamine resin or non - woven fabric, and the thickness is 0.1 - 0.2 mm.

[0047] The present invention also discloses a preparation method of a wood - stone floor, including the following steps:

[0048] 1) Preparation of the substrate layer

[0049] By weight, 40 - 70 parts of wood fiber, 20 - 50 parts of stone powder, 2 - 10 parts of adhesive, 5 - 20 parts of magnesium hydroxide, 2 - 10 parts of sodium hydroxide, and 1 - 10 parts of nano - titanium dioxide are stirred and mixed evenly. Subsequently, 5 - 13 parts of flame retardant and the remaining adhesive are added, and stirring and mixing are continued until evenly mixed. Then it is paved and formed, and hot - pressed at 170 - 240 °C and 15 - 40 MPa for 1 - 4 min; after cooling, it is cut into slab blanks to obtain the required substrate layer;

[0050] 2) Cover the upper surface of the substrate layer with a decorative paper impregnated with melamine resin, and the impregnation amount of melamine resin is 100 - 200 g / m 2, cover the balance layer on the lower surface of the substrate layer, and press it at 170 - 220 °C and 8 - 18 MPa for 20 - 60 s to cure the melamine resin and bond it with the substrate layer.

[0051] Example 1

[0052] As Figure 1 shown, a wood - stone floor includes a surface layer 1 and a substrate layer 2 arranged in sequence from top to bottom. The surface layer 1 includes a wear - resistant layer 3 and a balance layer 4 arranged in sequence from top to bottom. The preparation raw materials of the substrate layer 2 include wood fiber, stone powder, adhesive, magnesium hydroxide, sodium hydroxide, nano - titanium dioxide, and aluminum hydroxide flame retardant.

[0053] The preparation raw materials of the substrate layer include the following components in parts by weight:

[0054] 60 parts of wood fiber

[0055] 35 parts of stone powder

[0056] 5 parts of adhesive

[0057] 8 parts of magnesium hydroxide

[0058] 5 parts of sodium hydroxide

[0059] 5 parts of nano - titanium dioxide.

[0060] 5 parts of aluminum hydroxide flame retardant.

[0061] The particle size of the stone powder is 90 mesh.

[0062] The adhesive is a compound of pre - gelatinized starch and styrene - acrylic emulsion in a weight ratio of 2:1.

[0063] The density of the substrate layer is 0.7 g / cm 3 , and the thickness is 6 mm.

[0064] The wear - resistant layer is decorative paper impregnated with melamine resin, and the thickness is 0.2 mm.

[0065] The balance layer is decorative paper impregnated with melamine resin, and the thickness is 0.2 mm.

[0066] A preparation method of a wood - stone floor includes the following steps:

[0067] 1) Substrate layer preparation

[0068] By weight, mix 60 parts of wood fiber, 35 parts of stone powder, 3 parts of adhesive, 8 parts of magnesium hydroxide, 5 parts of sodium hydroxide, and 5 parts of nano - titanium dioxide evenly, then add 5 parts of flame retardant and 2 parts of adhesive, continue to mix evenly, then lay and form, and hot - press at 170 °C and 25 MPa for 2 min;

[0069] 2) Cover the decorative papers impregnated with melamine resin on the upper and lower surfaces of the base material layer respectively. The impregnation amount of melamine resin is 150 g / m 2 , and press at 180 °C and 15 MPa for 40 s to cure the melamine resin and bond it with the base material layer.

[0070] Example 2

[0071] As Figure 1 shown, a wood-stone floor includes a surface layer 1 and a base material layer 2 arranged in sequence from top to bottom. The surface layer 1 includes a wear-resistant layer 3 and a balance layer 4 arranged in sequence from top to bottom. The preparation raw materials of the base material layer 2 include wood fiber, stone powder, adhesive, magnesium hydroxide, sodium hydroxide, and nano-titanium dioxide.

[0072] The preparation raw materials of the base material layer include the following components in parts by weight:

[0073] 70 parts of wood fiber

[0074] 20 parts of stone powder

[0075] 5 parts of adhesive

[0076] 5 parts of magnesium hydroxide

[0077] 2 parts of sodium hydroxide

[0078] 1 part of nano-titanium dioxide.

[0079] The particle size of the stone powder is 80 mesh.

[0080] The adhesive is prepared by compounding pregelatinized starch and styrene-acrylic emulsion according to a weight ratio of 4:1.

[0081] The density of the base material layer is 0.9 g / cm 3 , and the thickness is 8 mm.

[0082] The wear-resistant layer and the balance layer are respectively decorative papers impregnated with melamine resin, and the thickness is 0.2 mm.

[0083] A preparation method of a wood-stone floor includes the following steps:

[0084] 1) Preparation of the base material layer

[0085] By weight, mix 70 parts of wood fiber, 20 parts of stone powder, 2 parts of adhesive, 5 parts of magnesium hydroxide, 2 parts of sodium hydroxide, and 1 part of nano-titanium dioxide evenly, then add 5 parts of flame retardant and the remaining adhesive, continue to mix evenly, and then lay and form. Hot press at 240 °C and 30 MPa for 1 min;

[0086] 2) Cover the decorative paper impregnated with melamine resin on the upper surface of the base material layer. The impregnation amount of melamine resin is 200 g / m 2, cover the balance layer on the lower surface of the base material layer, and press it at 170 °C and 15 MPa for 60 s to cure the melamine resin and bond it with the base material layer.

[0087] The rest is the same as in Example 1.

[0088] Example 3

[0089] As Figure 1 shown, a wood-stone floor includes a surface layer 1 and a base material layer 2 arranged in sequence from top to bottom. The surface layer 1 includes a wear-resistant layer 3 and a balance layer 4 arranged in sequence from top to bottom. The preparation raw materials of the base material layer 2 include wood fiber, stone powder, adhesive, magnesium hydroxide, sodium hydroxide, nano-titanium dioxide, and aluminum hydroxide flame retardant.

[0090] The preparation raw materials of the base material layer include the following components in parts by weight:

[0091] 40 parts of wood fiber

[0092] 50 parts of stone powder

[0093] 15 parts of adhesive

[0094] 20 parts of magnesium hydroxide

[0095] 10 parts of sodium hydroxide

[0096] 10 parts of nano-titanium dioxide

[0097] 13 parts of aluminum hydroxide flame retardant.

[0098] The particle size of the stone powder is 90 mesh.

[0099] The adhesive is prepared by compounding pregelatinized starch and styrene-acrylic emulsion in a weight ratio of 2:3.

[0100] The side of the base material layer is provided with a tongue-and-groove lock for easy splicing and installation.

[0101] The density of the base material layer is 0.7 g / cm 3 , and the thickness is 12 mm.

[0102] The wear-resistant layer is decorative paper impregnated with melamine resin, and the thickness is 0.15 mm.

[0103] The balance layer is non-woven fabric, and the thickness is 0.2 mm.

[0104] A preparation method of a wood-stone floor includes the following steps:

[0105] 1) Preparation of the base material layer

[0106] By weight, 40 parts of wood fiber, 50 parts of stone powder, 10 parts of adhesive, 20 parts of magnesium hydroxide, 10 parts of sodium hydroxide, and 10 parts of nano-titanium dioxide are stirred and mixed evenly. Subsequently, 13 parts of flame retardant and the remaining adhesive are added, and stirring and mixing continue until evenly distributed. Then, it is paved and formed, and hot-pressed at 180 °C and 20 MPa for 3 min;

[0107] 2) Cover the upper surface of the substrate layer with decorative paper impregnated with melamine resin, and the impregnation amount of melamine resin is 100 g / m 2 , cover the lower surface of the substrate layer with a balance layer, and press-mold at 200 °C and 18 MPa for 30 s to cure the melamine resin and bond it to the substrate layer.

[0108] The rest is the same as in Example 1.

[0109] Perform performance tests on the wood-stone floor obtained in Example 1. The results are as follows: flexural strength 45 MPa, formaldehyde release amount 0.02 mg / m 3 , meeting the ENF-level standard, surface abrasion resistance rotation number > 9000 rotations, conforming to the AC4 commercial grade, 24-hour water absorption expansion rate 6.5%, oxygen index ≥ 30, achieving B1-level flame retardancy.

[0110] For the parts or structures not specifically described in the present invention, existing technologies or existing products can be used, and no further elaboration will be made here.

[0111] The above are only the embodiments of the present invention, and do not limit the patent scope of the present invention accordingly. Any equivalent structural or equivalent process transformations made using the content of the specification of the present invention, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of the present invention.

Claims

1. A wood-stone floor, characterized in that: The wood-stone floor comprises a surface layer and a substrate layer arranged in sequence from top to bottom, wherein the surface layer comprises a wear-resistant layer and a balance layer arranged in sequence from top to bottom, and the raw materials for preparing the substrate layer comprise wood fiber, stone powder, adhesive, magnesium hydroxide, sodium hydroxide and nano titanium dioxide, and the formaldehyde emission of the wood-stone floor is ≤0.025mg / m 3 .

2. The wood-stone floor according to claim 1, characterized in that: The raw materials for preparing the substrate layer include the following components in parts by weight: 40-70 parts of wood fiber 20-50 parts of stone powder Adhesive 5-15 parts 5-20 parts of magnesium hydroxide 2-10 parts of sodium hydroxide 1-10 parts of nano titanium dioxide.

3. The wood-stone floor according to claim 2, characterized in that: The raw materials for preparing the substrate layer also include 5-13 parts of flame retardant, and the oxygen index of the wood-stone floor is ≥30.

4. The wood-stone floor according to claim 1, characterized in that: The particle size of the stone powder is ≤100 mesh.

5. The wood-stone floor according to claim 1, characterized in that: The adhesive is environmentally friendly melamine-modified urea adhesive or isocyanate adhesive or pregelatinized starch and styrene-acrylic emulsion compounded in a weight ratio of 2-4:1-3.

6. The wood-stone floor according to claim 1, characterized in that: The substrate layer has a density of ≥0.7 g / cm3 and a thickness of 6-12 mm.

7. The wood-stone floor according to claim 1, characterized in that: The sides of the base material layer are provided with tenon-tongue-groove lock buckles to facilitate splicing and installation.

8. The wood-stone floor according to claim 1, characterized in that: The wear-resistant layer is decorative paper impregnated with melamine resin and has a thickness of 0.1-0.2 mm.

9. The wood-stone floor according to claim 1, characterized in that: The balancing layer is decorative paper or non-woven fabric impregnated with melamine resin, and has a thickness of 0.1-0.2 mm.

10. The method for preparing a wood-stone floor according to any one of claims 1 to 9, characterized in that: The following steps are involved: 1) Preparation of substrate layer By weight, 40-70 parts of wood fiber, 20-50 parts of stone powder, 2-10 parts of adhesive, 5-20 parts of magnesium hydroxide, 2-10 parts of sodium hydroxide, and 1-10 parts of nano titanium dioxide are stirred and mixed evenly, and then 5-13 parts of flame retardant and the remaining adhesive are added, and the mixture is stirred and mixed evenly, and then paved and formed, and hot pressed at 170-240°C and 15-40MPa for 1-4 minutes; After cooling, the substrate is cut into slabs to obtain the required substrate layer; 2) Cover the upper surface of the substrate layer with decorative paper impregnated with melamine resin, the impregnation amount of melamine resin is 100-200g / m 2 , cover the balance layer on the lower surface of the substrate layer, and mold it for 20-60s at 170-220°C and 8-18MPa to solidify the melamine resin and combine it with the substrate layer.

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