A-grade fireproof decorative floor and manufacturing process thereof

Abstract

The invention discloses an A-grade fireproof decorative floor which comprises a ceramic wear-resistant layer, a decorative layer, an inorganic flame-retardant transition layer, a basalt fiber reinforced base material layer and a honeycomb aluminum foil backing layer. The ceramic wear-resistant layer is made of a transparent or semitransparent ceramic material; the decorative layer adopts microcrystalline glass sheets to form imitation wood grains or stone grains through digital ink-jet printing; the inorganic flame-retardant transition layer comprises a synergistic flame-retardant system of layered double hydroxides and expanded graphite; the basalt fiber reinforced base material layer is compounded with expanded perlite and modified basalt chopped fiber by taking magnesium cement as a gelatinizing agent to form a porous inorganic composite material. When the LDHs are heated, crystal water and CO2 are released and used for diluting oxygen, metal oxide is generated through decomposition at high temperature, a compact ceramic protection layer is formed, and heat and oxygen are isolated; and metal oxide generated by decomposition of LDHs is combined with the expanded carbon layer of the expanded graphite to form a composite barrier, so that the fire endurance is improved.

Description

Technical Field

[0001] The present invention relates to the technical field of building decoration materials, and particularly to an A-level fireproof decorative floor and its manufacturing process. Background Art

[0002] Decorative floors are an indispensable decoration material in the decoration process. Laying floors not only improves the comfort when people walk, but also can achieve an aesthetic effect through the splicing of floors with decorative patterns.

[0003] The fireproof function of decorative floors is particularly important, but the current decorative floors have the following problems:

[0004] (1) Wood-based substrate floors generally only reach B1-level flame retardancy and are difficult to meet the A-level fireproof standard;

[0005] (2) Traditional flame retardant treatment uses halogen-containing flame retardants, which have the problem of releasing toxic gases when burning;

[0006] (3) The fireproof performance of the interface between the decorative layer and the substrate is poor, and it is easy to delaminate at high temperatures. Summary of the Invention

[0007] In view of the deficiencies of the prior art, the present invention provides an A-level fireproof decorative floor and its manufacturing process to solve the problem of poor fireproof grade of existing decorative boards mentioned in the above background art.

[0008] To solve the above technical problems, the present invention provides the following technical solutions:

[0009] An A-level fireproof decorative floor, from top to bottom, includes: a ceramic wear-resistant layer, a decorative layer, an inorganic flame retardant transition layer, a basalt fiber reinforced substrate layer, and a honeycomb aluminum foil backing layer; the ceramic wear-resistant layer is made of a transparent or semi-transparent ceramic material; the decorative layer is formed by digital inkjet printing on a microcrystalline glass sheet to form a wood grain or stone texture, and a SiO2 aerogel transparent coating is covered on the surface; the inorganic flame retardant transition layer contains a synergistic flame retardant system of layered double hydroxides and expanded graphite, and is loaded with a flame retardant and an antibacterial agent; the basalt fiber reinforced substrate layer uses magnesium cement as a gelling agent, and is compounded with expanded perlite and modified basalt chopped fibers to form a porous inorganic composite material; the honeycomb aluminum foil backing layer is formed by pressing aluminum foil into a hexagonal honeycomb structure, namely a honeycomb core, and aluminum foil is covered on the upper and lower surfaces, and is compounded with the honeycomb core through an adhesive or hot pressing process to form a "sandwich" sandwich structure.

[0010] Preferably, the thickness of the ceramic wear-resistant layer is 0.1-0.3 mm, the thickness of the decorative layer is 0.5-1 mm, the thickness of the inorganic flame retardant transition layer is 1-2 mm, the thickness of the basalt fiber reinforced substrate layer is 8-12 mm, and the thickness of the honeycomb aluminum foil backing layer is 0.5-0.8 mm.

[0011] Preferably, the ceramic material is SiO2 aerogel or Al2O3 nano - coating, and its visible light transmittance reaches 80% - 90%.

[0012] Preferably, the double - hydroxide is formed by the alternating stacking of positively charged metal hydroxide layers and interlayer anions to form a "sandwich" structure. Through intercalation or surface modification, a flame retardant and an antibacterial agent are loaded. The loading amount of the flame retardant is 35 - 45%, and the loading amount of the antibacterial agent is 24 - 38%.

[0013] Preferably, the particle size of the composite expanded perlite is 0.5 - 2 mm, the length of the modified basalt chopped fiber is 3 - 6 mm, and the dosage is 15 - 25 wt%.

[0014] The present invention also provides a manufacturing process for an A - class fire - proof decorative floor, which includes the following steps:

[0015] Step 1: Prepare a basalt fiber - reinforced substrate layer: Mix 200 - mesh to 300 - mesh light - burned magnesia, a magnesium sulfate solution with a Baume degree of 25 - 30°, expanded perlite with a particle size of 0.5 - 2 mm, and modified basalt chopped fibers with a length of 3 - 6 mm and a dosage of 15 - 25 wt% in a ratio of 5:3:1.5:0.5. Add 0.3 - 0.6% of a foaming agent, and use a molding - foaming composite molding process to control the dosage of the foaming agent. Keep the pressure at 1.5 - 2.5 MPa for 20 - 30 minutes, and after molding, carry out steam curing at 60°C for 8 hours;

[0016] Step 2: Prepare an inorganic flame - retardant transition layer: Mix layered double - hydroxide LDHs and expanded graphite in a ratio of 2:1, use silica sol as a carrier, and scrape - coat it on the surface of the basalt fiber - reinforced substrate layer, with a coating amount of 300 g / m 2 ;

[0017] Step 3: Prepare a honeycomb aluminum foil backing layer: Press the aluminum foil to form a hexagonal honeycomb structure, namely, a honeycomb core, with a thickness of 0.05 - 0.1 mm and a pore diameter of 3 - 10 mm. Then cover the upper and lower surfaces of the honeycomb core with aluminum foil with a thickness of 0.1 - 0.3 mm, and composite it with the honeycomb core through an adhesive or hot - pressing process to form a "sandwich" sandwich structure, and composite the honeycomb aluminum foil backing layer to the other side of the basalt fiber - reinforced substrate layer through a hot - pressing composite process;

[0018] Step 4: Prepare a decorative layer: Form a wood - grain or stone - like texture on the microcrystalline glass sheet by digital ink - jet printing, and cover it with a SiO2 aerogel transparent coating on the surface. Then, subject the printed microcrystalline glass sheet to Ar plasma treatment and hot - press - composite it with the inorganic flame - retardant transition layer;

[0019] Step 5: Pre-coat the surface of the decorative layer with an optically transparent primer whose refractive index matches that of the ceramic layer, and then use a vacuum hot pressing composite process to bond the ceramic layer and the decorative layer, eliminating air bubbles and interfacial impurities to avoid optical path distortion.

[0020] Step 6: Roll-coat a UV-curable coating containing nano-SiO2 and cure it with ultraviolet light to obtain a decorative floor.

[0021] Preferably, the foaming agent in Step 1 is aluminum powder.

[0022] Compared with the prior art, the present invention has the following beneficial effects:

[0023] (1) Combining magnesium cement foaming material with basalt fiber reinforcement technology improves the mechanical properties while maintaining the fireproof advantage of inorganic materials.

[0024] (2) Layered double hydroxides release crystal water and CO2 when heated, which is used to dilute oxygen and decompose into metal oxides such as MgO and Al2O3 at high temperatures to form a dense ceramicized protective layer, isolating heat and oxygen. At the same time, interlayer anions such as PO4 3- can capture free radicals and inhibit smoke generation.

[0025] (3) The metal oxides generated by the decomposition of layered double hydroxides combine with the expanded carbon layer of expanded graphite to form a "ceramic-carbon layer" composite barrier, improving the fire resistance limit. Compared with traditional halogen-based flame retardants, layered double hydroxides are non-toxic and halogen-free, meeting environmental protection standards such as RoHS.

[0026] (4) A "heat barrier - thermal insulation layer" dual protection system is formed through the honeycomb aluminum foil backing layer and the porous substrate layer. Description of the Drawings

[0027] Figure 1 It is a schematic diagram of a decorative floor;

[0028] Figure 2 It is a process flow chart of the manufacturing process of a decorative floor;

[0029] In the figure: 1 - ceramic wear-resistant layer, 2 - decorative layer, 3 - inorganic flame retardant transition layer, 4 - basalt fiber reinforced substrate layer, 5 - honeycomb aluminum foil backing layer. Detailed Embodiments

[0030] The following will clearly and completely describe the technical solutions in the embodiments of the present invention with reference to the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present invention.

[0031] Example 1

[0032] Please refer to Figure 1 , a Class A fireproof decorative floor, which includes from top to bottom: a ceramic wear-resistant layer 1 with a thickness of 0.1 - 0.3 mm, a decorative layer 2 with a thickness of 0.5 - 1 mm, an inorganic flame-retardant transition layer 3 with a thickness of 1 - 2 mm, a basalt fiber-reinforced substrate layer 4 with a thickness of 8 - 12 mm, and a honeycomb aluminum foil backing layer 5 with a thickness of 0.5 - 0.8 mm.

[0033] The ceramic wear-resistant layer 1 is made of transparent or semi-transparent ceramic material, and the ceramic material is SiO2 aerogel or Al2O3 nano-coating, and its visible light transmittance reaches 80% - 90%, ensuring that the pattern of the decorative layer is clearly visible.

[0034] The decorative layer 2 is made of microcrystalline glass flakes, and is formed with wood grain or stone texture by digital inkjet printing, and is covered with a SiO2 aerogel transparent coating on the surface.

[0035] The inorganic flame-retardant transition layer 3 contains a synergistic flame-retardant system of layered double hydroxides and expanded graphite, and is loaded with a flame retardant and an antibacterial agent. The loading amount of the flame retardant is 35% - 45%, and the loading amount of the antibacterial agent is 24% - 38%.

[0036] Among them, layered double hydroxides, abbreviated as LDHs, are a class of inorganic materials with a unique layered structure, and the chemical general formula is:

[0037] [M 2+ 1-x M 3+ x (OH)2]^(x+)(A n- )_{x / n}·mH2O

[0038] Where:

[0039] M 2+ is a divalent metal cation (such as Mg 2+ , Zn 2+ , Ca 2+ , etc.)

[0040] M 3+ is a trivalent metal cation (such as Al 3+ , Fe 3+ , Cr 3+ , etc.)

[0041] A n- is an interlayer anion (such as CO3 2- , NO3 - , Cl - , etc.)

[0042] x is the molar ratio of the trivalent metal (usually 0.2 ≤ x ≤ 0.33)

[0043] m is the number of crystal water molecules

[0044] Layered structure of LDHs nanosheets: Single-layer nanosheets are prepared by ultrasonic exfoliation and alternately stacked by positively charged metal hydroxide layers (main layers) and interlayer anions (compensating charges) to form a "sandwich" structure. The thickness of the layer board is 0.5 - 1 nm.

[0045] The LDHs nanosheets and the expanded graphite sheets (with a thickness of 10 - 100 nm) are alternately compounded to form a "sandwich" structure, which expands synergistically during combustion to form a dense heat insulation layer.

[0046] When LDHs is heated, it releases crystal water and CO2 to dilute oxygen, decomposes at high temperature to form metal oxides such as MgO and Al2O3, forming a dense ceramicized protective layer to isolate heat and oxygen. At the same time, interlayer anions such as PO4 3- can capture free radicals and inhibit smoke generation. The metal oxides produced by the decomposition of LDHs combine with the expanded carbon layers of expanded graphite to form a "ceramic-carbon layer" composite barrier, improving the fire resistance limit. Compared with traditional halogen-based flame retardants, layered double hydroxides are non-toxic and halogen-free, meeting environmental protection standards such as RoHS.

[0047] The basalt fiber-reinforced substrate layer 4 uses magnesium cement as a gelling agent and is compounded with expanded perlite (particle size 0.5 - 2 mm) and modified short basalt fibers (length 3 - 6 mm, dosage 15 - 25 wt%) to form a porous inorganic composite material. For the first time, the magnesium cement foaming material is combined with the basalt fiber reinforcement technology to improve the mechanical properties while maintaining the fire protection advantages of inorganic materials, and the flexural strength is ≥8 MPa.

[0048] The honeycomb aluminum foil backing layer 5 is formed by die-pressing aluminum foil into a hexagonal honeycomb structure, namely the honeycomb core, with aluminum foil covering both the upper and lower surfaces and being compounded with the honeycomb core through an adhesive or hot pressing process to form a "sandwich" sandwich structure. The core functions of the honeycomb aluminum foil backing layer in the fireproof floor are as follows:

[0049] (1) Thermal barrier effect

[0050] Reflecting radiant heat: The surface reflectivity of the aluminum foil is ≥85%, and it can reflect more than 80% of the radiant heat energy in a fire.

[0051] Retarding heat conduction: The closed air units in the honeycomb structure have a low thermal conductivity (about 0.05 W / (m·K)), significantly reducing the heat transfer rate to the substrate layer.

[0052] (2) Structural reinforcement

[0053] Compressive and flexural strength: The honeycomb structure can withstand a pressure of 5 - 15 MPa in the vertical direction, enhancing the floor's resistance to deformation (elastic modulus reaching 1 - 3 GPa).

[0054] Vibration damping and energy absorption: The honeycomb cells absorb impact energy through plastic deformation, reducing the risk of floor fragmentation.

[0055] (3) Fire prevention cooperation

[0056] Oxygen barrier: The melting point of aluminum foil is 660 °C. At high temperatures, a dense aluminum oxide layer (Al2O3) is formed, blocking the contact between oxygen and the substrate.

[0057] Inhibiting smoke and toxicity: Aluminum foil is non-combustible and releases no smoke. When combined with the inorganic substrate layer, it can reduce the smoke toxicity index (in accordance with the GB / T20285 standard).

[0058] (4) Additional functions

[0059] Moisture and mothproof: The aluminum foil layer isolates water vapor penetration (water vapor transmission rate < 0.1 g / (m 2 ·d)), protecting the substrate from moisture corrosion.

[0060] Electromagnetic shielding: The conductivity of aluminum foil can attenuate electromagnetic waves by 30 - 50 dB (frequency range 1 - 10 GHz).

[0061] Example 2

[0062] A manufacturing process for A-level fireproof decorative floors, including the following steps:

[0063] Step 1: Prepare the basalt fiber-reinforced substrate layer: Mix light-burned magnesium oxide (200 mesh), magnesium sulfate solution (Baume degree 25°), expanded perlite (particle size 0.5 mm), and modified basalt chopped fibers (length 3 mm, dosage 15 wt%) in a ratio of 5:3:1.5:0.5. Add a foaming agent (0.3% aluminum powder), and use a molding - foaming composite process. Control the dosage of the foaming agent, hold the pressure at 1.5 MPa for 20 minutes, and after molding, perform steam curing at 60 °C for 8 h;

[0064] Step 2: Prepare the inorganic flame-retardant transition layer: Mix layered double hydroxide LDHs (Mg - Al system) and expanded graphite (particle size 50 μm) in a ratio of 2:1, use silica sol as a carrier, and scrape - coat it on the surface of the basalt fiber-reinforced substrate layer, with a coating amount of 300 g / m 2 ;

[0065] Step 3: Prepare the honeycomb aluminum foil backing layer: The aluminum foil is formed into a hexagonal honeycomb structure, i.e., the honeycomb core, with a thickness of 0.05 mm and a pore diameter of 3 mm. Then, aluminum foils with a thickness of 0.1 mm are covered on the upper and lower surfaces of the honeycomb core and are compounded with the honeycomb core through an adhesive or hot pressing process to form a "sandwich" sandwich structure. The honeycomb aluminum foil backing layer is compounded on the other side of the basalt fiber reinforced substrate layer through a hot pressing compounding process;

[0066] Step 4: Prepare the decorative layer: The microcrystalline glass sheet is formed with a wood grain or stone texture through digital inkjet printing, and a SiO2 aerogel transparent coating is covered on the surface. Then, the printed microcrystalline glass sheet is treated with Ar plasma. Through plasma surface activation treatment, a chemical bond is formed between the ceramic layer and the decorative layer, such as a Si-O-Si bond, rather than a simple physical covering, to ensure the optical uniformity of the interface. Then, it is hot pressed and compounded with the inorganic flame retardant transition layer;

[0067] Step 5: Pre-coat an optical grade transparent primer on the surface of the decorative layer, whose refractive index matches that of the ceramic layer. Then, a vacuum hot pressing compounding process is used to combine the ceramic layer and the decorative layer to eliminate air bubbles and interface impurities and avoid optical path distortion. Among them, digital inkjet uses high-temperature resistant inorganic pigments (such as cobalt blue, iron oxide red) to ensure no fading in the subsequent ceramic layer coating process. The nano-ceramic wear-resistant layer uses a transparent or semi-transparent ceramic material (such as SiO2 aerogel or Al2O3 nano-coating), and its visible light transmittance can reach 80%-90% to ensure that the pattern of the decorative layer is clearly visible.

[0068] Step 6: Roll coat a UV curable coating containing nano-SiO2 (solid content ≥ 95%), and cure it with ultraviolet light (wavelength 365 nm, intensity 800 mJ / cm 2 ) to obtain the decorative floor.

[0069] Example 3

[0070] A manufacturing process for a Class A fireproof decorative floor, comprising the following steps:

[0071] Step 1: Prepare the basalt fiber reinforced substrate layer: Mix light burned magnesia (200 mesh), magnesium sulfate solution (Baume degree 28°), expanded perlite (particle size 1.2 mm), and modified basalt chopped fibers (length 4.5 mm, dosage 22.5 wt%) in a ratio of 5:3:1.5:0.5, add a foaming agent (aluminum powder 0.45%), and use a molding - foaming composite molding process to control the dosage of the foaming agent, keep the pressure at 2 MPa for 25 minutes, and perform steam curing at 60°C for 8 h after molding;

[0072] Step 2: Prepare the inorganic flame-retardant transition layer: Mix layered double hydroxides LDHs (Mg-Al system) and expanded graphite (particle size 50 μm) at a ratio of 2:1, use silica sol as the carrier, and scrape and coat it on the surface of the basalt fiber-reinforced substrate layer, with a coating amount of 300 g / m 2 ;

[0073] Step 3: Prepare the honeycomb aluminum foil backing layer: Press the aluminum foil to form a hexagonal honeycomb structure, namely the honeycomb core, with a thickness of 0.08 mm and a pore diameter of 7 mm. Then cover the upper and lower surfaces of the honeycomb core with aluminum foil with a thickness of 0.2 mm, and compound it with the honeycomb core through an adhesive or hot pressing process to form a "sandwich" sandwich structure, and compound the honeycomb aluminum foil backing layer on the other side of the basalt fiber-reinforced substrate layer through a hot pressing and compounding process;

[0074] Step 4: Prepare the decorative layer: Form a wood grain or stone texture on the microcrystalline glass sheet by digital inkjet printing, and cover it with a SiO2 aerogel transparent coating on the surface. Then, subject the printed microcrystalline glass sheet to Ar plasma treatment. Through plasma surface activation treatment, a chemical bond is formed between the ceramic layer and the decorative layer, such as the Si-O-Si bond, rather than a simple physical covering, to ensure the optical uniformity of the interface; then hot press and compound it with the inorganic flame-retardant transition layer;

[0075] Step 5: Pre-coat an optical-grade transparent primer on the surface of the decorative layer, whose refractive index matches that of the ceramic layer. Then, use a vacuum hot pressing and compounding process to combine the ceramic layer and the decorative layer, eliminate air bubbles and interface impurities, and avoid optical path distortion. Among them, digital inkjet uses high-temperature resistant inorganic pigments (such as cobalt blue, iron oxide red) to ensure that it does not fade during the subsequent ceramic layer coating process. The nano-ceramic wear-resistant layer uses transparent or semi-transparent ceramic materials (such as SiO2 aerogel or Al2O3 nano-coating), and its visible light transmittance can reach 80%-90%, ensuring that the pattern of the decorative layer is clearly visible.

[0076] Step 6: Roll coat a UV-curable coating containing nano-SiO2 (solid content ≥ 95%), and cure it with ultraviolet light (wavelength 365 nm, intensity 800 mJ / cm 2 ) to obtain a decorative floor.

[0077] Example 4

[0078] A manufacturing process for Class A fireproof decorative floor, including the following steps:

[0079] Step 1: Prepare the basalt fiber reinforced substrate layer: Mix light burned magnesia (300 mesh), magnesium sulfate solution (Baume degree 30°), expanded perlite (particle size 2 mm), and modified basalt chopped fibers (length 6 mm, dosage 25 wt%) in a ratio of 5:3:1.5:0.5. Add a foaming agent (aluminum powder 0.6%), and adopt a molding - foaming composite forming process. Control the dosage of the foaming agent, keep the pressure at 2.5 MPa for 30 minutes, and then perform steam curing at 60°C for 8 hours after molding;

[0080] Step 2: Prepare the inorganic flame - retardant transition layer: Mix layered double - hydroxide LDHs (Mg - Al system) and expanded graphite (particle size 50 μm) in a ratio of 2:1, use silica sol as the carrier, and scrape - coat it on the surface of the basalt fiber reinforced substrate layer, with a coating amount of 300 g / m 2 ;

[0081] Step 3: Prepare the honeycomb aluminum foil backing layer: Press the aluminum foil to form a hexagonal honeycomb structure, namely the honeycomb core, with a thickness of 0.1 mm and a pore diameter of 10 mm. Then cover the upper and lower surfaces of the honeycomb core with aluminum foil with a thickness of 0.3 mm, and composite it with the honeycomb core through an adhesive or hot - pressing process to form a "sandwich" sandwich structure, and then composite the honeycomb aluminum foil backing layer on the other side of the basalt fiber reinforced substrate layer through a hot - pressing composite process;

[0082] Step 4: Prepare the decorative layer: Form a wood - grain or stone - like texture on the microcrystalline glass sheet by digital ink - jet printing, and coat a SiO2 aerogel transparent coating on the surface. Then, treat the printed microcrystalline glass sheet with Ar plasma. Through plasma surface activation treatment, a chemical bond such as Si - O - Si bond is formed between the ceramic layer and the decorative layer, rather than simple physical covering, to ensure the optical uniformity of the interface; then thermally press - composite it with the inorganic flame - retardant transition layer;

[0083] Step 5: Pre - coat an optical - grade transparent primer with a refractive index matching that of the ceramic layer on the surface of the decorative layer, and then use a vacuum hot - pressing composite process to combine the ceramic layer and the decorative layer, eliminating air bubbles and interface impurities to avoid light path distortion. Among them, digital ink - jet uses high - temperature - resistant inorganic pigments (such as cobalt blue, iron oxide red) to ensure no fading in the subsequent ceramic layer coating process. The nano - ceramic wear - resistant layer uses transparent or semi - transparent ceramic materials (such as SiO2 aerogel or Al2O3 nano - coating), and its visible light transmittance can reach 80% - 90% to ensure that the pattern of the decorative layer is clearly visible.

[0084] Step 6: Roll - coat a UV - curable coating containing nano - SiO2 (solid content ≥ 95%), and cure it with ultraviolet light (wavelength 365 nm, intensity 800 mJ / cm 2 ) to obtain a decorative floor.

[0085] The test performance of the fire - proof decorative floor obtained by the above method is as follows:

[0086] Table 1 Fire Resistance Performance Test

[0087]

[0088] Table 2 Physical and Mechanical Properties

[0089]

[0090] Table 3 Decoration Durability

[0091]

[0092]

[0093] Table 4 Environmental Protection Performance

[0094]

[0095] Table 5 Long-term Stability Test

[0096]

[0097] Table 6 Comparative Experiment (with Traditional Class B1 Fireproof Flooring)

[0098] Performance indicators This patented floor Traditional Class B1 floor Advantage improvement FIGRA (W / s) 98 250-350 Reduce by 60% - 70% <![CDATA[THR(MJ / m 2 )]]> 6.8 15-20 Reduce by 55% - 65% Smoke density (SDR) 12 50-80 Smoke suppression effect improved by 75% Abrasion resistance revolutions 8000 2000-4000 Service life extended by 2 - 3 times TVOC emission <![CDATA[0.018mg / m 3 > <![CDATA[0.1-0.3mg / m 3 > Environmental protection improved by 5 - 10 times

[0099] Explanation of Experimental Data Test Institution: The data are from the test reports of the National Building Materials Testing Center (CNBM) and SGS, a third-party testing agency.

[0100] Sample Preparation: Produced according to the process of Patent Example 1, with dimensions of 600×600×12 mm, and humidity equilibrium treatment (23℃ / 50%RH×72 h).

[0101] Core Advantages:

[0102] Fire Resistance Performance: The LDHs / expanded graphite synergistic system increases the char residue rate to 65%, far exceeding that of traditional flame retardants (30% - 40%).

[0103] Environmental Friendliness: The inorganic material system avoids organic volatiles, and the TVOC data meets the food-grade safety standard (refer to GB50325-2020).

[0104] Durability: The hardness of the nano-ceramic layer is close to that of sapphire, and the wear resistance is more than 10 times that of solid wood flooring.

[0105] Technical verification conclusion: Through systematic material innovation and process design, this decorative floor significantly surpasses existing products in key indicators such as fire prevention, environmental protection, and decorative lifespan. Experimental data fully verifies that it meets the requirements of Class A fire prevention standard (GB / T8624) and green building certifications (LEED / WELL), and has the value of industrial promotion.

[0106] It should be noted that the term "comprising", "including" or any other variant thereof is intended to cover non-exclusive inclusion, such that a process, method, article or device comprising a series of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article or device. Without further limitation, an element defined by the phrase "comprising a..." does not exclude the presence of additional identical elements in the process, method, article or device comprising said element.

[0107] Although embodiments of the present invention have been shown and described, it will be understood by those of ordinary skill in the art that various changes, modifications, substitutions and variations can be made to these embodiments without departing from the principles and spirit of the present invention. The scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A Class A fireproof decorative floor, characterized in that: From top to bottom, it includes: Ceramic wear-resistant layer (1), decorative layer (2), inorganic flame-retardant transition layer (3), basalt fiber-reinforced substrate layer (4), honeycomb aluminum foil backing layer (5); The ceramic wear-resistant layer (1) is made of transparent or semi-transparent ceramic material; The decorative layer (2) is formed by digital inkjet printing on a microcrystalline glass sheet to form a wood grain or stone texture, and is covered with a SiO2 aerogel transparent coating on the surface; The inorganic flame-retardant transition layer (3) contains a synergistic flame-retardant system of layered double hydroxides and expanded graphite, and is loaded with a flame retardant and an antibacterial agent; The basalt fiber-reinforced substrate layer (4) uses magnesium cement as a gelling agent, and is compounded with expanded perlite and modified basalt short-cut fibers to form a porous inorganic composite material; The honeycomb aluminum foil backing layer (5) is formed by pressing aluminum foil into a hexagonal honeycomb structure, namely a honeycomb core. The upper and lower surfaces are covered with aluminum foil, and are compounded with the honeycomb core through an adhesive or hot pressing process to form a "sandwich" sandwich structure.

2. The A-level fireproof decorative floor according to claim 1, wherein: The thickness of the ceramic wear-resistant layer is 0.1 - 0.3 mm, the thickness of the decorative layer is 0.5 - 1 mm, the thickness of the inorganic flame-retardant transition layer is 1 - 2 mm, the thickness of the basalt fiber-reinforced substrate layer is 8 - 12 mm, and the thickness of the honeycomb aluminum foil backing layer is 0.5 - 0.8 mm.

3. The A-level fireproof decorative floor according to claim 2, characterized in that: The ceramic material is SiO2 aerogel or Al2O3 nano-coating, and its visible light transmittance reaches 80% - 90%.

4. The A-level fireproof decorative floor according to claim 3, characterized in that: The double hydroxide is formed by alternating stacking of positively charged metal hydroxide layers and interlayer anions to form a "sandwich" structure. Through intercalation or surface modification, a flame retardant and an antibacterial agent are loaded. The loading amount of the flame retardant is 35 - 45%, and the loading amount of the antibacterial agent is 24 - 38%.

5. A Class A fireproof decorative floor according to claim 1, characterized in that: The particle size of the compounded expanded perlite is 0.5 - 2 mm, the length of the modified basalt short-cut fibers is 3 - 6 mm, and the dosage is 15 - 25 wt%.

6. The A-level fireproof decorative floor according to claim 1, characterized in that: The thickness of the honeycomb core is 0.05 - 0.1 mm, the pore diameter is 3 - 10 mm, and the thickness of the aluminum foil covering the upper and lower surfaces is 0.1 - 0.3 mm.

7. The manufacturing process of a Class A fireproof decorative floor according to claim 6, characterized in that: It includes the following steps: Step 1: Prepare the basalt fiber-reinforced substrate layer: Mix 200 - 300 mesh light-burned magnesia, magnesium sulfate solution with a Baume degree of 25 - 30°, expanded perlite with a particle size of 0.5 - 2 mm, and modified basalt short-cut fibers with a length of 3 - 6 mm and a dosage of 15 - 25 wt% in a ratio of 5:3:1.5:0.

5. Add 0.3 - 0.6% of a foaming agent, and use a molding-foaming composite molding process to control the dosage of the foaming agent. Keep the pressure at 1.5 - 2.5 MPa for 20 - 30 minutes, and after molding, cure with steam at 60°C for 8 hours; Step 2: Prepare an inorganic flame-retardant transition layer: Mix layered double hydroxides (LDHs) and expanded graphite in a ratio of 2:1, use silica sol as a carrier, scrape and coat it on the surface of the basalt fiber reinforced substrate layer, and the coating amount is 300 g / m 2 ; Step 3: Prepare the honeycomb aluminum foil backing layer: Press aluminum foil into a hexagonal honeycomb structure, namely a honeycomb core, with a thickness of 0.05 - 0.1 mm and a pore diameter of 3 - 10 mm. Then cover the upper and lower surfaces of the honeycomb core with aluminum foil with a thickness of 0.1 - 0.3 mm, and compound with the honeycomb core through an adhesive or hot pressing process to form a "sandwich" sandwich structure, and compound the honeycomb aluminum foil backing layer to the other side of the basalt fiber-reinforced substrate layer through a hot pressing composite process; Step 4: Prepare the decorative layer: The microcrystalline glass sheet is subjected to digital inkjet printing to form a wood grain or stone texture, and a SiO2 aerogel transparent coating is applied on the surface. Then, the printed microcrystalline glass sheet is treated with Ar plasma and then hot-pressed and compounded with an inorganic flame-retardant transition layer; Step 5: Pre-coat an optical-grade transparent primer on the surface of the decorative layer, the refractive index of which matches that of the ceramic layer. Then, a vacuum hot-pressing composite process is used to bond the ceramic layer and the decorative layer to eliminate bubbles and interfacial impurities and avoid optical path distortion; Step 6: Roll-coat a UV-curable coating containing nano-SiO2 and cure it with ultraviolet light to obtain a decorative floor.

8. The manufacturing process of a Class A fireproof decorative floor according to claim 7, characterized in that: The blowing agent in Step 1 is aluminum powder.

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