Floor structure with mute effect and production process

Abstract

The invention discloses a floor structure with a mute effect, which is characterized in that point molding is performed at the bottom of a floor to form point molding shape parts with different shapes so as to achieve the mute effect. The high polymer material used for plastic dispensing is one or more of TPE, PU, PVC, silicone rubber, EVA, PP, PE, ABS, TPO, TPU, PA or nylon. The plastic dispensing process disclosed by the invention is relatively low in cost, and particularly has obvious advantages in large-scale production. And the plastic dispensing material is tightly combined with the floor, is not easy to fall off, and is better in durability. The point plastic floor is easier to clean and maintain, and the problems possibly caused by a mute film are reduced. The silence effect of the point plastic floor can reach the level of a common silence film, and the point plastic floor can completely replace the silence film.

Description

Technical Field

[0001] The present invention discloses a floor structure with a sound insulation effect and a production process, belonging to the technical field of floors. Background Art

[0002] In the current technology, in order to make the floor have a sound insulation effect, a sound insulation film is laid at the bottom of the floor to achieve the sound insulation effect. The sound insulation film has the following advantages:

[0003] 1. Sound insulation and noise reduction

[0004] Reducing noise transmission: The sound insulation film can effectively absorb and block footsteps, furniture moving sounds, etc., reducing noise interference between floors.

[0005] Enhancing privacy: In multi-story buildings, the sound insulation film reduces the sound transmission between upper and lower floors, improving privacy.

[0006] 2. Vibration damping and buffering

[0007] Absorbing impact: The sound insulation film can absorb the impact when walking or an object drops, reducing the vibration of the floor and the underlying structure.

[0008] Protecting the floor: The vibration damping function extends the service life of the floor, reducing wear and damage.

[0009] 3. Moisture-proof and humidity-proof

[0010] Blocking moisture: The sound insulation film has a moisture-proof function, preventing ground moisture from penetrating into the floor and avoiding deformation and rot.

[0011] Mildew and bacteria prevention: The moisture-proof function reduces the growth of mildew and bacteria, keeping the indoor environment healthy.

[0012] 4. Heat preservation and heat insulation

[0013] Improving heat preservation: The sound insulation film has a certain heat insulation performance, reducing heat loss and enhancing the indoor heat preservation effect.

[0014] Energy conservation and environmental protection: By improving heat preservation, reducing heating and cooling energy consumption, achieving the purpose of energy conservation.

[0015] 5. Levelling the ground

[0016] Filling gaps: The sound insulation film can fill small unevenness on the ground, providing a smoother laying foundation.

[0017] Enhancing stability: The flat ground enhances the stability of the floor, reducing squeaking and looseness.

[0018] 6. Convenient installation

[0019] Simplifying construction: The sound insulation film is usually easy to lay, simplifying the installation process and saving time and labor.

[0020] Strong compatibility: applicable to various types of floors, such as wooden floors, composite floors, ceramic tiles, etc.

[0021] However, soundproof membranes also have the following disadvantages:

[0022] High cost: The material and production costs are relatively high, especially for high-quality soundproof membranes with a more expensive price.

[0023] Adhesion problem: It may fall off or shift after long-term use, affecting the effect.

[0024] Environmental protection: Some soundproof membranes may contain harmful chemical substances, with poor environmental protection.

[0025] Complex maintenance: Once damaged, it is more troublesome to replace or repair. Summary of the Invention

[0026] In the prior art, there has been no case of directly applying dot plastic at the bottom of the floor to replace the soundproof membrane. The reasons are as follows:

[0027] Limitations of dot plastic technology:

[0028] Dot plastic forms a specific shape through local coating or injection molding of materials. Although it can provide a certain shock absorption effect, its sound insulation and moisture-proof effects are limited, and it is difficult to achieve the overall performance of the soundproof membrane.

[0029] Cost and durability:

[0030] The durability of dot plastic is inferior to that of the soundproof membrane, and problems such as falling off or aging may occur after long-term use.

[0031] In order to overcome the above deficiencies, the present invention provides a floor structure with a soundproof effect and a production process by designing improvements in the formula and process of the dot plastic technology.

[0032] The technical solution of the present invention is as follows:

[0033] A floor structure with a soundproof effect, where dot plastic is applied at the bottom of the floor to form dot plastic shaped parts of different shapes to achieve the soundproof effect.

[0034] The polymer material used for dot plastic is one or more of TPE, PU, PVC, silicone rubber, EVA, PP, PE, ABS, TPO, TPU, PA, or nylon.

[0035] The material of the floor is one of solid wood floor, composite floor, laminate floor, PVC floor, rubber floor, linoleum floor, bamboo floor, metal floor, and epoxy resin floor.

[0036] The shape of the dot plastic shaped part is composed of one or more shapes such as dot shape, strip shape, continuous curve shape, polygon shape, etc.

[0037] The thickness of the dot-shaped portion is controlled within 1.0 mm - 2.0 mm.

[0038] A dot-shaped portion of a floor with a sound insulation effect, and the formulation of the dot-shaped portion is as follows:

[0039] Matrix material: 80 - 90% TPU, providing excellent elasticity, abrasion resistance and shock absorption performance, suitable for the dynamic load at the bottom of the floor.

[0040] Plasticizer: 5 - 10% phthalate plasticizer, improving the flexibility and adhesion of the material, and enhancing the bonding performance with the floor substrate.

[0041] Filler: 3 - 5% calcium carbonate, reducing the cost while improving the hardness and abrasion resistance of the material.

[0042] Flame retardant: 2 - 3% aluminum hydroxide or phosphorus-based flame retardant, improving the flame retardant performance to meet safety requirements.

[0043] Antioxidant and stabilizer: 0.5 - 1% antioxidant 1010, preventing material aging and extending the service life.

[0044] UV stabilizer: 0.5 - 1%, preventing material degradation caused by ultraviolet rays.

[0045] Adhesion promoter: 1 - 2% silane coupling agent, enhancing the adhesion of the material to the floor substrate.

[0046] Sound absorption additive: 2 - 3% rubber particles or elastic microspheres, improving the sound insulation and shock absorption performance and reducing noise transmission.

[0047] Formulation characteristics:

[0048] High elasticity: The TPU matrix provides excellent shock absorption performance, suitable for the dynamic load at the bottom of the floor.

[0049] Abrasion resistance: The combination of TPU and calcium carbonate enhances the abrasion resistance of the material.

[0050] Strong adhesion: Silane coupling agent and plasticizer ensure the firm bonding of the material to the floor substrate.

[0051] Good sound insulation effect: Adding rubber particles or elastic microspheres to improve the sound insulation performance.

[0052] Aging resistance: Antioxidant and UV stabilizer extend the service life of the material.

[0053] The percentages in the above formulation are mass ratios.

[0054] A production process for a floor with a sound insulation effect, including the following steps:

[0055] (1) Mix the dot molding material evenly according to the above formula ratio;

[0056] (2) Heat the mixed material to the molten state, and control the temperature at 150 - 200 °C;

[0057] (3) Ensure that the material has moderate fluidity for easy dot molding construction;

[0058] (4) According to the floor size and dot molding requirements, set the discharge amount, dot molding spacing, and dot molding height of the dispensing machine or injection molding machine;

[0059] (5) Carry out dot molding operation, and evenly apply the molten material on the bottom of the floor through the dispensing machine or injection molding machine;

[0060] (6) Use a hot air gun or infrared heater to heat the dot molding part to promote the bonding between the material and the floor substrate. The heating temperature is 80 - 120 °C and lasts for 1 - 2 minutes;

[0061] (7) Naturally cool or accelerate cooling through an air cooling device to completely cure the dot molding material;

[0062] (8) Ensure that the dot molding part is tightly bonded to the floor substrate without falling off or cracking.

[0063] The present invention also provides another formula for the dot molding shape part of the floor with a sound - proof effect, and the formula is as follows:

[0064] TPE matrix: 70 - 80%, TPE has good elasticity, wear resistance and resilience, and is suitable as the main matrix material.

[0065] Filler: calcium carbonate 10 - 15%, reducing costs while improving the hardness and wear resistance of the material.

[0066] Plasticizer: phthalates 5 - 10%, improving flexibility and processing performance.

[0067] Foaming agent: azodicarbonamide 2 - 5%, generating a microporous structure to enhance the shock absorption and sound - proof effects.

[0068] Cross - linker: dicumyl peroxide 1 - 2%, improving the strength and durability of the material.

[0069] Antioxidant and stabilizer: antioxidant 1010 0.5 - 1%, preventing material aging and extending service life.

[0070] UV stabilizer: 0.5 - 1%, preventing material degradation caused by ultraviolet rays.

[0071] Lubricant: zinc stearate 0.5 - 1%, preventing material degradation caused by ultraviolet rays.

[0072] Flame retardant: 1-2% of aluminum hydroxide or phosphorus-based flame retardant, which improves the flame retardancy performance and meets the safety requirements.

[0073] The percentages in the above formula are by mass ratio.

[0074] Formula features:

[0075] High elasticity: TPE provides excellent mechanical properties and durability, suitable for scenarios with high-frequency use.

[0076] Wear resistance: The combination of TPE and calcium carbonate enhances the wear resistance of the material.

[0077] Flexibility: Plasticizers make the material easier to process and enhance the flexibility of the finished product.

[0078] Good sound insulation effect: The foaming agent generates a microporous structure, enhancing the shock absorption and sound insulation effects and improving comfort.

[0079] Aging resistance: Antioxidants and UV stabilizers extend the service life of the material.

[0080] A production process for a floor with a sound insulation effect, including the following steps:

[0081] (a) Drying: Dry the TPE particles and fillers at 80-100°C for 2-4 hours to remove moisture;

[0082] (b) Mixing: Mix the TPE matrix, fillers, plasticizers, foaming agents, cross-linking agents, stabilizers, and lubricants evenly according to the above ratios;

[0083] (c) Extrusion molding

[0084] Extruder temperature settings:

[0085] Feeding section: 160-170°C

[0086] Compression section: 170-180°C

[0087] Metering section: 180-190°C

[0088] Die head: 190-200°C

[0089] Extrusion pressure: Adjust according to the equipment specifications to ensure uniform extrusion of the material;

[0090] Foaming control: By controlling the extrusion speed and temperature, the foaming agent is evenly foamed during extrusion to form a microporous structure;

[0091] (d) Dotting process

[0092] Dotting equipment: Use a high-precision dotting machine to ensure accurate dotting position and thickness;

[0093] Dot plasticizing temperature: 180 - 200 °C;

[0094] Dot plasticizing pressure: Adjust according to the floor material and thickness to ensure good bonding between the TPE material and the bottom of the floor;

[0095] Cooling and shaping: Immediately cool after dot plasticizing to ensure rapid shaping of the TPE material and maintain the microporous structure;

[0096] (e) Inspection: Check the uniformity and bonding strength of the dot plasticizing layer to ensure sound insulation, shock absorption and resilience effects.

[0097] The beneficial effects of the present invention are:

[0098] Cost - effectiveness: The cost of the dot plasticizing process is relatively low, especially with obvious advantages in large - scale production.

[0099] Strong adhesion: The dot plasticizing material bonds tightly with the floor, is not easy to fall off, and has better durability.

[0100] Customization: The size, density and distribution of the dots can be adjusted according to requirements to provide better sound insulation and shock absorption effects.

[0101] Environmental protection: The dot plasticizing material is usually more environmentally friendly and meets modern environmental protection requirements.

[0102] Easy maintenance: The dot plasticizing floor is easier to clean and maintain, reducing the problems that may be brought by the sound insulation film.

[0103] Substitutability: The sound insulation effect of the dot plasticizing floor can reach the level of ordinary sound insulation film and can completely replace the sound insulation film. Specific implementation mode

[0104] The present invention will be further described below in conjunction with embodiments. The following embodiments are only used to more clearly illustrate the technical solution of the present invention and cannot be used to limit the protection scope of the present invention.

[0105] Embodiment 1: Solid wood floor + TPU dot plasticizing formula

[0106] Floor structure:

[0107] Floor material: Solid wood floor

[0108] Dot plasticizing material:

[0109] TPU 85%

[0110] Phthalate plasticizer 8%

[0111] Calcium carbonate 4%

[0112] Aluminum hydroxide flame retardant 2%

[0113] Antioxidant 1010 0.5%

[0114] UV stabilizer 0.5%

[0115] Silane coupling agent 1%

[0116] Rubber particles 2%

[0117] Dot-shaped plastic part: dot-shaped, thickness 1.5 mm

[0118] Production process:

[0119] Mixing materials: Mix TPU, plasticizer, calcium carbonate, flame retardant, antioxidant, UV stabilizer, silane coupling agent and rubber particles evenly according to the formula ratio.

[0120] Heating: Heat the mixed materials to 180 °C to make them melt.

[0121] Dotting operation: Use a dispensing machine to evenly dot the molten material on the bottom of the solid wood floor, with a dotting spacing of 10 mm and a dotting height of 1.5 mm.

[0122] Heating and bonding: Use a hot air gun to heat the dotted part to 100 °C for 1.5 minutes to promote the bonding of the material to the floor substrate.

[0123] Cooling: Naturally cool to room temperature to ensure that the dotted material is completely cured.

[0124] Inspection: Check the uniformity and bonding strength of the dotted layer to ensure that there is no peeling or cracking.

[0125] Example 2: Composite floor + TPE dotting formula

[0126] Floor structure:

[0127] Floor material: Composite floor

[0128] Dotting material:

[0129] TPE matrix 75%

[0130] Calcium carbonate 12%

[0131] Phthalate plasticizer 8%

[0132] Azodicarbonamide blowing agent 3%

[0133] Dicumyl peroxide crosslinking agent 1.5%

[0134] Antioxidant 1010 0.5%

[0135] UV stabilizer 0.5%

[0136] Zinc stearate lubricant 0.5%

[0137] 1% Aluminum Hydroxide Flame Retardant

[0138] Dot-shaped Molding Part: Strip Shape, Thickness 1.8 mm

[0139] Production Process:

[0140] Drying: Dry the TPE particles and calcium carbonate at 90 °C for 3 hours to remove moisture.

[0141] Mixing: Mix the TPE matrix, calcium carbonate, plasticizer, foaming agent, crosslinking agent, antioxidant, UV stabilizer, lubricant, and flame retardant evenly according to the formula ratio.

[0142] Extrusion Molding:

[0143] Extruder Temperature Setting: Feeding Section 165 °C, Compression Section 175 °C, Metering Section 185 °C, Die Head 195 °C.

[0144] Extrusion Pressure: Adjust according to the equipment specifications to ensure uniform extrusion of the material.

[0145] Foaming Control: Control the extrusion speed and temperature to make the foaming agent foam evenly and form a microporous structure.

[0146] Dot-shaped Molding Process:

[0147] Dot-shaped Molding Temperature: 190 °C.

[0148] Dot-shaped Molding Pressure: Adjust according to the thickness of the composite floor to ensure good bonding between the TPE material and the bottom of the floor.

[0149] Cooling and Shaping: Cool immediately after dot-shaped molding to ensure rapid shaping of the TPE material and maintain the microporous structure.

[0150] Inspection: Check the uniformity and bonding strength of the dot-shaped molding layer to ensure sound insulation, shock absorption, and resilience effects.

[0151] Example 3: PVC Floor + TPU Dot-shaped Molding Formula

[0152] Floor Structure:

[0153] Floor Material: PVC Floor

[0154] Dot-shaped Molding Material:

[0155] 88% TPU

[0156] 7% Phthalate Plasticizer

[0157] 3% Calcium Carbonate

[0158] 1.5% Phosphorus-based Flame Retardant

[0159] 0.3% Antioxidant 1010

[0160] UV stabilizer 0.2%

[0161] Silane coupling agent 1%

[0162] Elastic microspheres 2%

[0163] Dot-shaped plastic part: continuous curve shape, thickness 1.2 mm

[0164] Production process:

[0165] Mixing materials: Mix TPU, plasticizer, calcium carbonate, flame retardant, antioxidant, UV stabilizer, silane coupling agent and elastic microspheres evenly according to the formula ratio.

[0166] Heating: Heat the mixed materials to 190 °C to make them molten.

[0167] Dot-shaped plastic operation: Use an injection molding machine to evenly inject the molten materials at the bottom of the PVC floor to form a continuous curve-shaped dot-shaped plastic part.

[0168] Heating and bonding: Use an infrared heater to heat the dot-shaped plastic part to 110 °C for 1 minute to promote the bonding between the materials and the floor substrate.

[0169] Cooling: Accelerate cooling through an air-cooling device to ensure the rapid curing of the dot-shaped plastic materials.

[0170] Inspection: Check the uniformity and bonding strength of the dot-shaped plastic layer to ensure no peeling or cracking.

[0171] Example 4: Bamboo floor + TPE dot-shaped plastic formula

[0172] Floor structure:

[0173] Floor material: Bamboo floor

[0174] Dot-shaped plastic material:

[0175] TPE matrix 78%

[0176] Calcium carbonate 10%

[0177] Phthalate plasticizer 6%

[0178] Azodicarbonamide blowing agent 4%

[0179] Dicumyl peroxide crosslinking agent 1%

[0180] Antioxidant 1010 0.5%

[0181] UV stabilizer 0.5%

[0182] Dot-shaped plastic part: polygonal shape, thickness 2.0 mm

[0183] Production process:

[0184] Drying: Dry the TPE pellets and calcium carbonate at 85 °C for 2.5 hours to remove moisture.

[0185] Mixing: Mix the TPE matrix, calcium carbonate, plasticizer, foaming agent, crosslinking agent, antioxidant, and UV stabilizer evenly according to the formulation ratio.

[0186] Extrusion molding:

[0187] Extruder temperature setting: Feeding section 160 °C, compression section 170 °C, metering section 180 °C, die head 190 °C.

[0188] Extrusion pressure: Adjust according to the equipment specifications to ensure uniform extrusion of the material.

[0189] Foaming control: By controlling the extrusion speed and temperature, make the foaming agent foam evenly to form a microporous structure.

[0190] Dot plastic process:

[0191] Dot plastic temperature: 185 °C.

[0192] Dot plastic pressure: Adjust according to the thickness of the bamboo floor to ensure good bonding between the TPE material and the bottom of the floor.

[0193] Cooling and shaping: Immediately cool after dot plastic to ensure rapid shaping of the TPE material and maintain the microporous structure.

[0194] Inspection: Check the uniformity and bonding strength of the dot plastic layer to ensure the sound insulation, shock absorption, and resilience effects.

[0195]

[0196] The impact noise pressure of the floors in the above 4 embodiments is lower than the standard of GB / T 50313-2014 "Code for Sound Insulation Design of Civil Buildings", indicating that the dot plastic floor can be fully applied to the floor industry and can replace the sound insulation pad.

[0197] The above are only the preferred embodiments of the present invention. It should be noted that for those of ordinary skill in the art, without departing from the technical principle of the present invention, several improvements and deformations can be made, and these improvements and deformations should also be regarded as the protection scope of the present invention.

Claims

1. A floor structure with a sound-proof effect, characterized in that: Dot molding is performed on the bottom of the floor to form dot molding parts of different shapes to achieve a sound-proof effect.

2. A floor structure with a sound-proofing effect according to claim 1, characterized in that: The polymer material used for the dot molding is one or more of TPE, PU, ​​PVC, silicone rubber, EVA, PP, PE, ABS, TPO, TPU, PA or nylon.

3. The floor structure with a sound-proofing effect according to claim 1, characterized in that: The material of the floor is one of solid wood floor, composite floor, laminate floor, PVC floor, rubber floor, linen floor, bamboo floor, metal floor and epoxy resin floor.

4. The floor structure with a sound-proofing effect according to claim 1, characterized in that: The shape of the point-molding shape part is composed of one or more shapes such as point shape, strip shape, continuous curve shape, polygon shape, etc.

5. The floor structure with a sound-proofing effect according to claim 1, characterized in that: The thickness of the point-molded shape portion is controlled to be 1.0 mm-2.0 mm.

6. A point-molded shape portion of a floor with a sound-proof effect, characterized in that: The formula for the dot-shaped part is as follows: Base material: TPU 80-90% Plasticizer: Phthalate plasticizer 5-10% Filler: Calcium carbonate 3-5% Flame retardant: aluminum hydroxide or phosphorus flame retardant 2-3% Antioxidant and stabilizer: Antioxidant 1010 0.5-1% UV stabilizer: 0.5-1% Adhesion promoter: silane coupling agent 1-2% Noise-absorbing additive: rubber particles or elastic microspheres 2-3% The percentages in the above formula are by mass.

7. A production process for a floor with a sound-absorbing effect, characterized in that The steps include: (1) Mix the dot molding materials evenly according to the formula ratio of claim 6; (2) Heat the mixed material to a molten state, and control the temperature at 150-200°C; (3) Ensure that the material has moderate fluidity to facilitate spot molding construction; (4) According to the floor size and dot molding requirements, set the dispensing machine or injection molding machine's output, dot molding spacing and dot molding height; (5) Dot molding operation: the molten material is evenly applied to the bottom of the floor through a dispensing machine or an injection molding machine; (6) Use a hot air gun or infrared heater to heat the plasticized area to promote the bonding between the material and the floor substrate. The heating temperature is 80-120°C for 1-2 minutes. (7) Cool naturally or accelerate cooling through air cooling equipment to completely solidify the point plastic material; (8) Ensure that the plasticized area is tightly bonded to the floor substrate without any peeling or cracking.

8. A point-molded shape portion of a floor with a sound-proof effect, characterized in that: The formula for the dot-shaped part is as follows: TPE matrix: 70-80% Filler: Calcium carbonate 10-15% Plasticizer: Phthalate esters 5-10% Foaming agent: azodicarbonamide 2-5% Crosslinking agent: dicumyl peroxide 1-2% Antioxidant and stabilizer: Antioxidant 1010 0.5-1% UV stabilizer: 0.5-1% Lubricant: Zinc stearate 0.5-1% Flame retardant: aluminum hydroxide or phosphorus flame retardant 1-2% The percentages in the above formula are by mass.

9. A production process for a floor with a sound-absorbing effect, characterized in that The steps include: (a) Drying: Dry the TPE particles and fillers at 80-100°C for 2-4 hours to remove moisture; (b) Mixing: uniformly mixing the TPE matrix, filler, plasticizer, foaming agent, cross-linking agent, stabilizer and lubricant according to the proportions of claim 8; (c) Extrusion molding Extruder temperature setting: Feeding section: 160-170℃ Compression section: 170-180℃ Metering section: 180-190℃ Die head: 190-200℃ Extrusion pressure: Adjust according to equipment specifications to ensure uniform extrusion of materials; Foaming control: By controlling the extrusion speed and temperature, the foaming agent can be foamed evenly during the extrusion process to form a microporous structure; (d) Point molding process Dot molding equipment: Use high-precision dot molding machines to ensure accurate dot molding position and thickness; Plasticizing temperature: 180-200℃; Point molding pressure: adjusted according to the floor material and thickness to ensure that the TPE material is well bonded to the bottom of the floor; Cooling and shaping: Cooling is performed immediately after point molding to ensure that the TPE material is quickly shaped and maintains a microporous structure; (e) Inspection: Check the uniformity and bonding strength of the plastic layer to ensure the quietness, shock absorption and rebound effects.

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