Surface layer for seam beautifying plate, seam beautifying plate and plate processing technology

Abstract

The invention relates to the technical field of layered products, in particular to a surface layer for a seam beautifying plate, the seam beautifying plate and a plate processing technology. The surface layer sequentially comprises a wear-resistant layer, a color film layer and a coloring middle material layer from top to bottom; the coloring middle material layer comprises the following components in parts by weight: 20-25 parts of PVC (Polyvinyl Chloride) resin powder; 15 to 25 parts of a plasticizer; 45 to 55 parts of a filling agent; 3-5 parts of a stabilizer; and 1-2 parts of color master batch. The coloring middle material layer is arranged to replace structures such as a seam beautifying film commonly adopted in the prior art to be used for exposing the seam beautifying plate, the physical performance and the like of the coloring middle material layer can be matched with those of materials such as a color film layer by controlling the use amount of the materials such as a filling agent in the coloring middle material layer, and the phenomenon that the color film layer cannot be exposed in the environments such as heating and damp is reduced. And the warping difference between the two is too large to cause material layering and the like.

Description

Technical Field

[0001] The present invention relates to the technical field of laminated products, and particularly to a surface layer for caulking boards, the caulking boards, and a board processing technology. Background Art

[0002] With the improvement of consumers' demand for the quality of interior decoration in the market, the joint treatment of floor covering materials has gradually become a key factor affecting aesthetics and other aspects. When traditional floors are laid, a gap of 1-3 mm needs to be reserved between adjacent plates to prevent arching or cracking caused by temperature and humidity changes. Usually, in order to pursue visual aesthetics, a caulking agent needs to be filled in the gap to achieve sealing and beautification.

[0003] However, common caulking processes have brought many problems, including but not limited to: long construction period and high labor cost; it is difficult to completely match the caulking color with the floor surface, and personalized design is limited. Therefore, related products such as caulking boards have gradually emerged and become popular in the market.

[0004] Such boards usually have a prefabricated joint decorative layer provided therein, and a gap is opened on the surface of the board to expose the joint decorative layer. Therefore, according to the needs of customers, different colors of joint decorative layers can be used in combination to reflect different colors of gaps, etc. In existing boards, a caulking film is usually provided as the joint decorative layer under the color film layer of the board. However, the physical properties between the caulking film and the color film layer are usually quite different, so the board is prone to delamination under conditions such as heat and moisture, which is not conducive to the popularization and use of caulking boards. Summary of the Invention

[0005] The present invention provides a surface layer for caulking boards. The surface layer has a colored coloring intermediate layer. After an exposed gap is opened on the surface layer, the decorative effect of the gap can be achieved by exposing the coloring intermediate layer. At the same time, under the composition ratio of the coloring intermediate layer, its physical properties are adapted to the adhered color film layer, etc., reducing the possibility of separation between the two under conditions such as heat and moisture.

[0006] The present invention is achieved by the following technical solutions: A surface layer for caulking boards, which sequentially includes a wear-resistant layer, a color film layer, and a coloring intermediate layer from top to bottom; in the coloring intermediate layer, by weight, it includes the following components: PVC resin powder: 20-25 parts; plasticizer: 15-25 parts; filler: 45-55 parts; stabilizer: 3-5 parts; color masterbatch: 1-2 parts.

[0007] As a further improvement of the present invention, the thickness of the wear-resistant layer is 0.5-0.6 mm, the thickness of the color film layer is 0.05-0.1 mm, and the thickness of the coloring intermediate layer is 0.7-1 mm.

[0008] In a second aspect, the present invention provides a caulking board, which includes, from top to bottom, any one of the above-mentioned surface layers for caulking boards, a base material layer, and a bottom material layer, wherein a caulking groove is formed on the surface layer for caulking boards.

[0009] As a further improvement of the present invention, the thickness of the base material layer is 2.0 - 4.8 mm, and the thickness of the bottom material layer is 1.5 - 2 mm.

[0010] As a further improvement of the present invention, a UV layer is further provided above the surface layer for caulking boards.

[0011] In a third aspect, the present invention provides a board processing process for processing any one of the above-mentioned caulking boards, including the following steps: S1. Weigh and mix the raw materials of the colored intermediate layer in proportion to obtain a first mixture; S2. Knead and open the first mixture, where the kneading time is 3 - 5 min, the opening temperature is 170 - 190 °C, and the opening time is 3 - 5 min to obtain a plasticized material; S3. Roll the plasticized material to a set size, cut it after cooling to obtain the colored intermediate layer; S4. Stack the wear-resistant layer, the color film layer, the colored intermediate layer, the base material layer, and the bottom material layer to form a primary board, and subject the primary board to hot pressing and cold pressing for temperature reduction and shaping in sequence to obtain the caulking board.

[0012] As a further improvement of the present invention, in S3, a four-roll rolling process is adopted, where the temperatures of the first roll and the second roll are both 170 - 180 °C, the temperature of the third roll is 150 - 160 °C, and the temperature of the fourth roll is 140 - 150 °C.

[0013] As a further improvement of the present invention, in S4, the hot pressing temperature is 13 - 150 °C, the hot pressing pressure is 3 - 7 MPa, and the hot pressing time is 25 - 35 min.

[0014] As a further improvement of the present invention, in S4, the cold pressing temperature is 25 - 35 °C, the cold pressing pressure is 7 - 13 MPa, and the cold pressing time is 30 - 40 min.

[0015] As a further improvement of the present invention, a UV coating treatment is further included between S3 and S4, including the following steps: A. Coat a UV coating on the upper surface of the colored intermediate layer, and the coating amount is 6 - 22 g / m2; B. Place the coated colored intermediate layer in a light baking oven for curing; C. Perform heat and cold shaping treatment on the cured colored intermediate layer.

[0016] The beneficial effects of the present invention include: (1) By setting up a coloring intermediate layer to replace structures such as caulking films commonly used in the prior art for exposure, on the one hand, in the present invention, by controlling the dosage of materials such as fillers in the coloring intermediate layer, its physical properties and other physical properties of materials such as color films are adapted, reducing the occurrence of situations such as material delamination caused by excessive warping differences between the two under environments such as heating and moisture; on the other hand, when this surface layer is applied to a board, a caulking groove needs to be opened on the board to expose the coloring intermediate layer, and the coloring intermediate layer in the present invention has a relatively small deformation amount under conditions such as moisture and heat, enabling the surface layer and the board made using this surface layer to achieve long-term storage, etc., which is conducive to the promotion and use of products.

[0017] (2) Under the preferred structure, in the present invention, the thickness of the coloring intermediate layer is controlled between 0.7 and 1 mm. Compared with the caulking film in the prior art, the thickness of which may only be 0.4 mm, when using the surface layer in the present invention to make a caulking board and then opening a caulking groove, the requirement for the opening accuracy of the depth of the caulking groove decreases. When a small amount of over-depth occurs due to errors during opening, the coloring intermediate layer still remains exposed instead of the board layer placed below, which is conducive to the increase in the processing success rate of the caulking board and further conducive to the promotion and use of the caulking board.

[0018] (3) Under this processing method, a surface layer can be prepared with a high yield, and without using glue, the combination between the surface layer, the base material layer, and the bottom material layer can be completed to process a caulking board. On the one hand, the yield of the caulking board is guaranteed; on the other hand, the layers in the board prepared by this processing method are tightly connected, making the overall physical properties of the board good, not prone to warping, etc., and thus making the board easy to store, transport, etc. Generally, it is conducive to the promotion and use of this processing method and the board product. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] The following drawings are provided for combination with the preferred embodiments in the present invention to help understand the purpose and advantages of the present invention, where: Figure 1 It is a schematic diagram of the structure of a caulking board from a top view perspective. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0020] The present invention will be further described in detail below with reference to the drawings and embodiments.

[0021] In this specification, orientation terms such as up, down, left, right, front, back, front side, back side, top, bottom, etc., which are mentioned or may be mentioned, are defined with respect to the structures shown in the respective drawings. The terms "inner" and "outer" respectively refer to the directions towards or away from the geometric center of a specific component. They are relative concepts and may accordingly change depending on their different positions and usage states. Therefore, these or other orientation terms should not be construed as restrictive terms.

[0022] Example 1: In this example, a caulking board is provided. Generally, from top to bottom, it sequentially includes a surface layer, a base material layer, and a bottom material layer. A caulking groove 1 is formed in the caulking board, and the bottom of the caulking groove 1 exposes the coloring intermediate layer in the surface layer. In this example, taking Figure 1 the shown perspective as an example, the caulking groove 1 is formed on the upper right side and the upper side of the upper surface of the board.

[0023] Specifically, the used surface layer is a surface layer for caulking board, which sequentially includes a 0.5 mm thick wear-resistant layer, a 0.05 mm thick color film layer, and a 0.7 mm thick coloring intermediate layer from top to bottom. Exemplarily, in this example, the wear-resistant layer is a transparent phenol-free wear-resistant layer produced by Jiangsu Dahui Plastic Co., Ltd., which is prepared from PVC resin, dioctyl terephthalate (hereinafter simply referred to as DOTP), stabilizer, etc.; the color film layer is a common commercially available printed color film. The coloring intermediate layer contains 25 parts of PVC resin, 20 parts of plasticizer, 50 parts of filler, 4 parts of stabilizer, and 1 part of masterbatch. Exemplarily, in this example, the used plasticizer is DOTP, the filler is calcium carbonate powder, the stabilizer is calcium-zinc stabilizer, and the masterbatch is titanium dioxide.

[0024] In this example, the base material layer is made of a commonly commercially available stone plastic composite (hereinafter simply referred to as SPC), which is usually prepared by mixing and extruding PVC resin, calcium powder, processing aids, etc. The thickness of the SPC base material layer in this example is 3 mm.

[0025] In this example, the bottom material layer is made of a commonly commercially available luxury vinyl tile (hereinafter simply referred to as LVT). The LVT bottom material layer is calendered from PVC resin, DOTP, calcium powder, calcium-zinc stabilizer, etc. The thickness of the LVT bottom material layer in this example is 1.9 mm.

[0026] The caulking board in this example is obtained through the following processing steps: S1. Weigh 25 parts of PVC resin, 20 parts of DOTP, 50 parts of calcium carbonate powder, 4 parts of calcium-zinc stabilizer, and 1 part of titanium dioxide as raw materials. Place each raw material in a high-speed mixer and mix evenly to obtain the first mixture. S2. Knead and open the first mixture. The kneading time is 5 min, the opening temperature is 180 °C, and the opening time is 5 min to obtain the plasticized material. S3. Four-roll calender the plasticized material. The temperature of the first roll is 175 °C, the temperature of the second roll is 170 °C, the temperature of the third roll is 155 °C, and the temperature of the fourth roll is 150 °C. Calender the plasticized material into a material with a thickness of 0.6 mm, and cut it after cooling to obtain the colored intermediate layer. S4. Place the canvas, release film, LVT bottom layer, SPC substrate layer, colored intermediate layer, color film layer, wear-resistant layer, release film, and embossing plate in the loading tray of the press in sequence. The LVT bottom layer, SPC substrate layer, colored intermediate layer, color film layer, wear-resistant layer, and release film together form the primary board, which is the prototype of the final product. The canvas is used to reduce buffering, the release film is used to facilitate demolding, and the embossing plate is used to press appropriate patterns on the surface of the board according to requirements. The materials placed on the loading tray are first subjected to hot pressing at a temperature of 140 °C, a pressure of 5 MPa, and a duration of 30 min, and finally converted to cold pressing. The temperature during cold pressing is 40 °C, the pressure is 10 MPa, and the duration is 30 min. Demold the product after cold pressing to obtain the caulking board.

[0027] Finally, according to the actual needs of consumers, caulk grooves 1 can be opened on the upper surface of the caulking board to expose the colored intermediate layer. In this embodiment, taking Figure 1 the shown perspective as an example, the caulk grooves 1 are opened on the right side and the upper side of the upper surface of the board, and the thickness of the caulk grooves 1 is 0.6 mm.

[0028] Example 2: The difference between this example and Example 1 is that in this example, the colored intermediate layer contains 20 parts of PVC resin, 22 parts of DOTP, 45 parts of calcium carbonate powder, 5 parts of calcium-zinc stabilizer, and 1 part of titanium dioxide as raw materials.

[0029] Example 3: The difference between this example and Example 1 is that in this example, the colored intermediate layer contains 24 parts of PVC resin, 19 parts of DOTP, 55 parts of calcium carbonate powder, 3 parts of calcium-zinc stabilizer, and 1 part of carbon black as raw materials.

[0030] Example 4: The difference between this embodiment and Embodiment 1 is that in this embodiment, the thickness of the wear-resistant layer is 0.5 mm, the thickness of the color film layer is 0.05 mm, the thickness of the intermediate coloring layer is 0.8 mm, the thickness of the substrate layer is 3 mm, and the thickness of the primer layer is 1.7 mm.

[0031] Embodiment 5: The difference between this embodiment and Embodiment 1 is that in this embodiment, the thickness of the wear-resistant layer is 0.5 mm, the thickness of the color film layer is 0.05 mm, the thickness of the intermediate coloring layer is 0.9 mm, the thickness of the substrate layer is 3 mm, and the thickness of the primer layer is 1.6 mm.

[0032] Embodiment 6: The difference between this embodiment and Embodiment 1 is that in this embodiment, a UV layer is further formed above the surface layer of the plate. Among them, the thickness of the wear-resistant layer is 0.5 mm, the thickness of the color film layer is 0.05 mm, the thickness of the intermediate coloring layer is 1.0 mm, the thickness of the substrate layer is 3 mm, and the thickness of the primer layer is 1.5 mm.

[0033] The UV layer is obtained through the following processing steps: A. After processing the intermediate coloring layer in S3, apply UV coating on the intermediate coloring layer, and the coating amount is 12 g / m 2 ; B. Place the coated intermediate coloring layer in a light baking oven for curing; C. Perform heat and cold setting treatment on the intermediate coloring layer after the UV layer is cured. Exemplarily, in this embodiment, first place the cured intermediate coloring layer in hot water to soften the substrate, and then place it in cold water for shrinkage setting of the intermediate coloring layer. Among them, it is necessary to immerse in hot water twice and in cold water once. When immersing in hot water for the first time, the hot water temperature is 98 °C; when immersing in hot water for the second time, the hot water temperature is 95 °C; when finally immersing in cold water, the cold water temperature is 25 ± 5 °C. During this period, it is necessary to maintain the transmission speed of the intermediate coloring layer at 15 m / min.

[0034] Preferably, before applying the UV coating, keep the surface temperature of the intermediate coloring layer ≤ 35 °C.

[0035] Preferably, transfer the intermediate coloring layer after heat and cold setting treatment to a curing room, control the room temperature at 22 ± 4 °C, the humidity at 40 - 80%, and cure for 48 h.

[0036] Comparative Example 1: The difference between this comparative example and Embodiment is that in this comparative example, the thickness of the wear-resistant layer is 0.5 mm, the thickness of the color film layer is 0.05 mm, the thickness of the intermediate coloring layer is 0.6 mm, the thickness of the substrate layer is 3 mm, and the thickness of the primer layer is 1.9 mm.

[0037] Comparative Example a: The sheet used in this comparative example is a commercially available sheet prepared by using the formula and preparation method disclosed in the patent with the application number 202020970036.3.

[0038] Performance testing: In this example, the warping performance of the caulking sheets in Examples 1 to 6 and Comparative Example 1 was tested. For the experimental methods without specific conditions noted, they were generally determined according to national standards. If there is no corresponding national standard, they were carried out according to general international standards, conventional conditions, or the conditions recommended by the manufacturer. In this example, the detection conditions for the warping resistance ability included detecting the warping situation of the sheet after being placed at 80 °C for 6 h, detecting the warping situation of the sheet after being placed at 46 °C for 24 h, and detecting the warping situation of the sheet after being placed at -15 °C for 6 h. The test results are shown in Table 1: Table 1 Summary of the warping test results of the sheets in Examples 1 to 4 and Comparative Example 1 Serial number Warpage at 80°C for 6 hours (≤1.0 mm) Warpage at 46°C for 24 hours (≤1.0 mm) Warpage at -15°C for 6 hours (≤1.0 mm) Example 1 0.3 mm 0.45 mm 0.2 mm Example 2 0.2 mm 0.35 mm 0.1 mm Example 3 0.1 mm 0.2 mm 0.2 mm Example 4 0.1 mm 0.2 mm 0.1 mm Example 5 0.2 mm 0.4 mm 0.2 mm Example 6 1.2 mm 0.8 mm 1.0 mm Comparative Example 1 -1.1 mm -0.75 mm -0.7 mm From the relevant test results of Examples 1 to 4 in the table, it can be seen that the caulking sheets prepared under the component requirements and the thickness requirements of each layer in the present invention have strong warping resistance ability. However, when the thickness of the coloring intermediate layer in the sheet is too large, as shown by the test results in Comparative Example 1, the warping resistance ability of the sheet decreases and it is difficult to meet the use requirements, that is, ≤ 1.0 mm. This proves that the coloring intermediate layer of the present invention plays a decisive role in adjusting the overall structural stability of the sheet, etc. on the premise of being able to provide beautifying functions such as color for the caulking groove 1. Furthermore, reasonable control of it can enable the sheet to have good mechanical properties, which is beneficial to the popularization and use of the caulking sheet.

[0039] Meanwhile, in this example, the caulking sheets in Example 1 and the common commercially available caulking sheets in Comparative Example a were also selected to carry out a number of performance tests. For the experimental methods without specific conditions noted, they were generally determined according to national standards. If there is no corresponding national standard, they were carried out according to general international standards, conventional conditions, or the conditions recommended by the manufacturer.

[0040] In Table 2, the relevant steps of the 28-day high humidity test item are as follows: (1) Product installation: Install the sheet in the test box. When installing, ensure that the screws fixing the sheet are flush with the surface of the sheet to make the whole sheet flat; after installation, use the MVER8000 dehumidifier to roll the exposed surface of the sheet to control the moisture; then seal the edge of the test area with tape.

[0041] (2) Initial situation recording: Turn off the overhead light inside the test chamber and turn on the side light (24V LED) inside the test chamber. Take an initial photo of the board, and use a tripod to fix the shooting angle and distance; for defects visible after the board is installed, directly mark them on the board with a marker pen.

[0042] (3)Water vapor release Release water vapor into the test chamber to change the humidity inside the chamber.

[0043] (4)Record of board changes: Frequency and personnel: Visually inspect the appearance of the board every two weeks by those with inspection qualifications; Light source sequence: First, turn on the overhead light inside the test chamber, evaluate and record the appearance of the board; second, evaluate and record the appearance of the board under indirect side light (using light reflection or a white screen); finally, evaluate and record the appearance of the board with the side light inside the test chamber directly turned on. Finally, summarize the appearance changes of the board after 28 days in a high-humidity environment.

[0044] The relevant test results of each test item are shown in Table 2.

[0045] Table 2 Summary of the test results of the board performance in Example 1 and Comparative Example a It can be seen from the test results in Table 2 that the caulking board in the present invention is significantly superior to the existing commercially available products in terms of stability, including peel strength, warpage resistance, etc. On the one hand, it makes the caulking board in the present invention easier to store, transport, etc.; on the other hand, when the caulking board in the present invention is actually used as a floor, etc., the deformation amount generated when it is heated and humidified is smaller, and it can meet the higher product requirements of consumers for warpage prevention, etc. Therefore, the caulking board in the present invention has high commercial value and has great advantages in popularization and use.

[0046] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those of ordinary skill in the art should understand that they can still modify the technical solutions recorded in the foregoing embodiments, or perform equivalent replacements for some of the technical features; and these modifications or replacements do not make the essence of the corresponding technical solutions deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A surface layer for a caulking board, characterized in that, The surface layer sequentially includes a wear-resistant layer, a color film layer, and a coloring intermediate layer from top to bottom; In the coloring intermediate layer, by weight, it includes the following components: PVC resin powder: 20 - 25 parts; plasticizer: 15 - 25 parts; filler: 45 - 55 parts; stabilizer: 3 - 5 parts; masterbatch: 1 - 2 parts.

2. The surface layer for a caulking board according to claim 1, characterized in that, The thickness of the wear-resistant layer is 0.5 - 0.6 mm, the thickness of the color film layer is 0.05 - 0.1 mm, and the thickness of the coloring intermediate layer is 0.7 - 1 mm.

3. A caulking board, characterized in that, The board includes a surface layer for a caulking board as described in any one of claims 1 or 2, a base material layer, and a bottom material layer from top to bottom, wherein a caulking groove is provided on the surface layer for the caulking board.

4. The caulking board according to claim 3, characterized in that, The thickness of the base material layer is 2.0 - 4.8 mm, and the thickness of the bottom material layer is 1.5 - 2 mm.

5. A caulking board according to claim 3, characterized in that, A UV layer is further provided above the surface layer for the caulking board.

6. A sheet processing technology, characterized in that, For processing a caulking board as described in any one of claims 3 - 5, it includes the following steps: S1. Weigh each raw material of the coloring intermediate layer in proportion and mix them to obtain a first mixture; S2. Carry out internal mixing and open mixing on the first mixture, where the internal mixing time is 3 - 5 min, the open mixing temperature is 170 - 190 °C, and the open mixing time is 3 - 5 min to obtain a plasticized material; S3. Calender the plasticized material to a set size, cut it after cooling to obtain the coloring intermediate layer; S4. Stack the wear-resistant layer, the color film layer, the coloring intermediate layer, the base material layer, and the bottom material layer to form a primary board, and subject the primary board to hot pressing and cold pressing for temperature reduction and shaping in sequence to obtain the caulking board.

7. A sheet processing process according to claim 6, characterized in that, In S3, a four-roll calendering process is adopted, where the temperatures of the first roll and the second roll are both 170 - 180 °C, the temperature of the third roll is 150 - 160 °C, and the temperature of the fourth roll is 140 - 150 °C.

8. A sheet processing process according to claim 6, characterized in that, In S4, the hot pressing temperature is 13 - 150 °C, the hot pressing pressure is 3 - 7 MPa, and the hot pressing time is 25 - 35 min.

9. A sheet processing process according to claim 6, characterized in that, In S4, the cold pressing temperature is 25 - 35 °C, the cold pressing pressure is 7 - 13 MPa, and the cold pressing time is 30 - 40 min.

10. A sheet processing process according to claim 6, characterized in that, An UV coating treatment is further included between S3 and S4, including the following steps: Apply UV coating on the upper surface of the color intermediate layer, with the coating amount being 6 - 22 g / m 2 ; Place the coated coloring intermediate layer in a light baking oven for photocuring; Carry out heat and cold shaping treatment on the photocured coloring intermediate layer.

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