Ceramic tile-like stone-plastic floor and preparation method thereof

Abstract

The invention discloses a ceramic tile-like stone-plastic floor and a preparation method thereof, and belongs to the technical field of composite floors. The tile-like stone-plastic floor comprises a wear-resistant layer, a decorative layer, a first hard SPC base material layer, a foaming SPC base material layer and a second hard SPC base material layer which are arranged from top to bottom, the first hard SPC base material layer is prepared from the following components in percentage by weight: 12 to 20 percent of polyvinyl chloride (PVC) resin, 12 to 20 percent of organic silicon modified acrylic resin, 50 to 70 percent of calcium carbonate and the balance of auxiliaries; a groove is formed in the tile-like stone-plastic floor from top to bottom, and the lowest point of the groove does not exceed half of the thickness of the first hard SPC base material layer. The groove is used for simulating the seam beautifying effect of the ceramic tile. The organic silicon modified acrylic resin is added in the hard SPC base material layer, so that the weather resistance, the water resistance, the wear resistance, the pollution resistance and other properties of the hard SPC base material layer can be effectively improved.

Description

Technical Field

[0001] The invention belongs to the technical field of composite floors, and particularly relates to a ceramic tile imitation stone plastic floor and a preparation method thereof. Background Art

[0002] With the development of architectural decorative materials, imitation marble tiles have gained popularity due to their aesthetics and durability. However, traditional imitation marble tiles are still considered ceramic tiles, and they come with issues such as heavy weight, complex installation, and high cost. Furthermore, when laying tiles, gaps will form between adjacent tiles. Currently, the best way to address this is to use caulking compound. Caulking compound is essentially a gel-like substance that combines various chemical components. Because the thermal expansion and contraction coefficients of caulking compound differ from those of the tiles themselves, it can age and fall off over time. Furthermore, during tile laying, issues such as specification and manual errors can also result in uneven tile heights.

[0003] Currently, there is a growing market demand for alternative materials that are aesthetically pleasing, lightweight, and easy to install.

[0004] SPC flooring (Stone Plastic Composite) has attracted much attention as a new type of flooring material. It is a composite board made of stone powder and thermoplastic polymer materials that are evenly mixed and then extruded at high temperature.

[0005] However, the surface decoration effect of SPC floor is single and it is difficult to meet the needs of high-end decoration. Therefore, it is of great significance to develop a multi-layer co-extruded SPC floor that has both the aesthetic effect of imitation marble tiles and the advantages of SPC floor. Summary of the Invention

[0006] The object of the present invention is to overcome at least one shortcoming of the prior art and provide a tile-like stone-plastic floor and a preparation method thereof.

[0007] The technical solution adopted in this application is:

[0008] A ceramic tile imitation stone plastic floor, comprising a wear-resistant layer, a decorative layer, a first hard SPC substrate layer, a foamed SPC substrate layer, and a second hard SPC substrate layer arranged from top to bottom;

[0009] The components of the first hard SPC substrate layer include 12-20 wt% of polyvinyl chloride resin (PVC), 12-20 wt% of silicone modified acrylic resin, 50-70 wt% of calcium carbonate, and the balance are additives and functional additives;

[0010] The imitation tile stone plastic floor is provided with grooves from top to bottom, wherein the lowest point of the grooves does not exceed half the thickness of the first hard SPC substrate layer; the grooves are used to simulate the beautiful seam effect of tiles.

[0011] In some embodiments, the second hard SPC substrate layer comprises 12-20 wt % of polyvinyl chloride resin (PVC), 12-20 wt % of silicone-modified acrylic resin, 50-70 wt % of calcium carbonate, and the remainder being additives and functional additives.

[0012] In some embodiments, the first hard SPC substrate layer and the second hard SPC substrate layer include the following raw materials in parts by weight: 20-30 parts of polyvinyl chloride resin (PVC), 80-110 parts of calcium carbonate, 2-4 parts of calcium zinc stabilizer, 2-4 parts of acrylate copolymer (ACR), 2-4 parts of toughening agent, 0.5-3 parts of internal lubricant, 0.5-3 parts of external lubricant, 0.1-0.5 parts of carbon black, and 20-30 parts of silicone modified acrylic resin.

[0013] In some embodiments, the raw materials for preparing the silicone-modified acrylic resin include silicone monomer and epoxy acrylic resin, wherein the silicone monomer accounts for 10%-50% of the total mass of the silicone monomer and epoxy acrylic resin, preferably 20-40%, and more preferably 30%-40%; and / or the viscosity of the silicone-modified acrylic resin is 1000-2000 mPa·s.

[0014] In some embodiments, the texture of the decorative layer includes at least one of wood texture, marble texture, granite texture, cloth texture, carpet texture, cement texture, and metal texture; preferably, marble texture.

[0015] In some embodiments, the foamed SPC substrate layer includes the following raw materials in parts by weight: 40-60 parts of polyvinyl chloride resin (PVC), 70-100 parts of calcium carbonate, 30-60 parts of SPC foaming regrind, 3-5 parts of calcium zinc stabilizer, 1-3 parts of acrylate copolymer (ACR), 5-10 parts of foaming regulator, 0.1-0.5 parts of yellow foaming agent, 0.1-0.3 parts of white foaming agent, 0.5-3 parts of internal lubricant, and 0.5-3 parts of external lubricant.

[0016] In some embodiments, a UV layer is provided above the wear-resistant layer; and / or a sound-absorbing layer is provided below the second hard SPC substrate layer.

[0017] In some embodiments, the thickness of the first hard SPC substrate layer is 0.8-1.2 mm, the thickness of the foamed SPC substrate layer is 3.2-12.0 mm, and the thickness of the second hard SPC substrate layer is 0.8-1.2 mm; and / or, the first hard SPC substrate layer, the foamed SPC substrate layer, and the second hard SPC substrate layer are prepared by a co-extrusion process.

[0018] In some embodiments, the grooves are formed by planing.

[0019] A method for preparing a tile-like stone-plastic floor comprises the following steps:

[0020] S1. The hard SPC substrate layer raw materials are heated and mixed; the foamed SPC substrate layer raw materials are heated and mixed;

[0021] S2. The hard SPC substrate layer raw material and the foamed SPC substrate layer raw material are transferred to the extruder;

[0022] S3. The foamed SPC substrate layer is injected into the mold through the central flow channel of the confluence core; the hard SPC substrate layer is injected into the mold through the side flow channel of the confluence core and co-extruded through a dispenser to form an upper layer of a first hard SPC substrate layer, an intermediate foamed SPC substrate layer, and a lower layer of a second hard SPC substrate layer. A rough plate;

[0023] S4. A decorative layer is provided on the first hard SPC substrate layer of the rough plate, and a wear-resistant layer is continued to be provided on the decorative layer;

[0024] S5. Coating a UV-curable transparent lacquer on the wear-resistant layer to form a UV layer;

[0025] S6. The plate passes through the plate roller and prints the pattern on the upper surface of the plate;

[0026] S7. Planing to form grooves with a beautiful seam effect. The planed part includes the UV layer, the wear-resistant layer, the decorative layer and part of the first hard SPC substrate layer. The lowest point of the planing does not exceed half the thickness of the first hard SPC substrate layer.

[0027] The beneficial effects of this application are:

[0028] 1. Achieve lightweight:

[0029] This application uses a co-extrusion process to obtain an ABA-type lightweight SPC substrate consisting of a first hard SPC substrate layer, a foamed SPC substrate layer, and a second hard SPC substrate layer. This can significantly reduce the weight of the floor, reduce transportation and installation costs, and improve user experience. The density of conventional SPC flooring is 1.9-2.1g / cm 3 The density of the ABA type SPC floor in this application is 1.4-1.6g / cm 3 , reducing weight by 20-30%.

[0030] 2. Improve decorative effect:

[0031] Through high-definition printing technology and transparent wear-resistant layer, and through planing, a beautiful seam appearance effect is formed, and a realistic imitation marble texture is achieved on the SPC floor to meet high-end decoration needs.

[0032] 3. By adding silicone-modified acrylic resin to the hard SPC substrate layer, the weather resistance, water resistance, wear resistance and stain resistance of the hard SPC substrate layer and the beauty seam grooves set in the layer can be effectively improved.

[0033] 4. Simplify the installation process:

[0034] The lock-type installation design does not require auxiliary materials, simplifies the installation process, and shortens the construction period.

[0035] 5. Enhance environmental protection:

[0036] Use recyclable environmentally friendly materials to reduce energy consumption in the production process and comply with green building standards.

[0037] 6. Optimize overall performance:

[0038] The ABA type three-in-one SPC base material layer is obtained through multi-layer co-extrusion technology, and the decorative layer, SPC base material layer and sound-absorbing layer are tightly combined to provide high wear resistance, stain resistance, sound insulation and comfort, meeting the use requirements of high-end places. BRIEF DESCRIPTION OF THE DRAWINGS

[0039] Figure 1 This is a schematic diagram of the caulking groove of the multi-layer co-extruded marble-like tile floor of this application (one side of the groove is planed).

[0040] Figure 2 for Figure 1 A magnified schematic diagram of the area marked by the circle in center A.

[0041] Figure 3 This is a schematic diagram of the beauty groove of the multi-layer co-extruded marble-like tile floor of this application (one side of the planed mother groove).

[0042] In the figure: 1, UV layer; 2, wear-resistant layer; 3, decorative layer; 4, first hard SPC substrate layer; 5, foamed SPC substrate layer; 6, second hard SPC substrate layer; 7, sound-absorbing layer (sound-absorbing pad). DETAILED DESCRIPTION

[0043] To make the objectives, technical solutions, and advantages of the present invention more clear, the technical solutions of the present invention are described clearly and completely below. Obviously, the embodiments described are only some of the embodiments of the present invention, not all of them. All other embodiments derived by persons of ordinary skill in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.

[0044] If no specific techniques or conditions are specified in the examples, the experiments were carried out according to the techniques or conditions described in the literature in the field or according to the product instructions. If no manufacturer is specified for the reagents or instruments used, they are all conventional products that can be purchased through regular channels.

[0045] The present application provides a tile-like stone plastic floor with a beautiful seam effect. The English name of stone plastic floor (SPC floor) is Stone Plastic Composite Flooring or Stone Polymer Composite Flooring. Figure 1 and Figure 2 . Figure 1 contains a circle area marked "A", Figure 2 yes Figure 1 The enlarged schematic diagram of the area marked by circle A in the middle. The imitation tile stone plastic floor comprises, from top to bottom, a UV layer 1, a wear-resistant layer 2, a decorative layer 3, a first hard SPC substrate layer 4, a foamed SPC substrate layer 5, a second hard SPC substrate layer 6, and a sound-absorbing layer (sound-absorbing pad) 7.

[0046] The first hard SPC substrate layer comprises 12-20 wt % of polyvinyl chloride (PVC) powder, 12-20 wt % of organosilicon-modified acrylic resin, 50-70 wt % of calcium carbonate, and the remainder is auxiliary agents and functional additives.

[0047] The imitation tile stone plastic floor is provided with grooves from top to bottom, wherein the lowest point of the grooves does not exceed half the thickness of the first hard SPC substrate layer; the grooves are used to simulate the beautiful seam effect of tiles.

[0048] In some embodiments, the second hard SPC substrate layer comprises 12-20 wt % of PVC resin powder, 12-20 wt % of silicone-modified acrylic resin, 50-70 wt % of calcium carbonate, and the remainder is additives and functional additives.

[0049] In some embodiments, the first hard SPC substrate layer and the second hard SPC substrate layer include the following raw materials in parts by weight: 20-30 parts of polyvinyl chloride resin (PVC), 80-110 parts of calcium carbonate, 2-4 parts of calcium zinc stabilizer, 2-4 parts of acrylate copolymer (ACR), 2-4 parts of toughening agent, 0.5-3 parts of internal lubricant, 0.5-3 parts of external lubricant, 0.1-0.5 parts of carbon black, and 20-30 parts of silicone modified acrylic resin.

[0050] Preferably, the first hard SPC substrate layer and the second hard SPC substrate layer include the following raw materials in parts by weight: 22-28 parts of polyvinyl chloride resin (PVC), 95-110 parts of calcium carbonate, 3-4 parts of calcium zinc stabilizer, 2.5-3.5 parts of acrylate copolymer (ACR), 2-3 parts of toughening agent, 0.5-2 parts of internal lubricant, 0.5-2 parts of external lubricant, 0.1-0.5 parts of carbon black, and 20-30 parts of silicone modified acrylic resin.

[0051] In some embodiments, the raw materials for preparing the organosilicon-modified acrylic resin include organosilicon monomer and epoxy acrylic resin, wherein the organosilicon monomer accounts for 10%-50% of the total mass of the organosilicon monomer and epoxy acrylic resin, preferably 20-40%, and more preferably 30%-40%.

[0052] In some embodiments, the viscosity of the organosilicon-modified acrylic resin is 1000-2000 mPa·s.

[0053] In some embodiments, the foamed SPC substrate layer includes the following raw materials in parts by weight: 40-60 parts of polyvinyl chloride resin (PVC), 70-100 parts of calcium carbonate, 30-60 parts of SPC foaming regrind, 3-5 parts of calcium zinc stabilizer, 1-3 parts of acrylate copolymer (ACR), 5-10 parts of foaming regulator, 0.1-0.5 parts of yellow foaming agent, 0.1-0.3 parts of white foaming agent, 0.5-3 parts of internal lubricant, and 0.5-3 parts of external lubricant.

[0054] Preferably, the foamed SPC substrate layer comprises the following raw materials in parts by weight: 40-60 parts of polyvinyl chloride resin (PVC), 80-90 parts of calcium carbonate, 35-50 parts of SPC foaming regrind, 3-5 parts of calcium zinc stabilizer, 2-3 parts of acrylate copolymer (ACR), 5-8 parts of foaming regulator, 0.1-0.5 parts of yellow foaming agent, 0.1-0.3 parts of white foaming agent, 0.5-2 parts of internal lubricant, and 0.5-2 parts of external lubricant.

[0055] In some embodiments, the particle size of calcium carbonate is 5-20 μm, preferably 5-15 μm.

[0056] In some embodiments, the texture of the decorative layer includes at least one of wood texture, marble texture, granite texture, cloth texture, carpet texture, cement texture, and metal texture, preferably marble texture. The decorative layer includes a decorative layer made of PVC color film, or a decorative layer printed with high-definition ink or digital printing.

[0057] In some embodiments, the wear-resistant layer is made of a highly transparent and wear-resistant modified polyvinyl chloride (PVC) resin.

[0058] In some embodiments, a UV layer is provided above the wear-resistant layer. The UV layer is obtained by coating with a UV curing transparent lacquer and then curing it. The coating amount of the UV curing transparent lacquer is 15 to 30 g / m 2 .

[0059] In some embodiments, the grooves are formed by planing, preferably using a high-speed rotating tool. The lowest point of the planing is no more than half the thickness of the first hard SPC substrate layer. The grooves are used to simulate the grouting effect of ceramic tiles.

[0060] In some embodiments, a sound absorbing layer, or a sound absorbing pad (e.g., Figure 1 The main function of the sound-absorbing layer is to reduce the noise generated by footsteps, furniture movement, and other ground activities. The sound-absorbing layer is typically made of materials such as IXPE, EVA, or cork. The sound-absorbing layer is bonded to the SPC base layer with glue.

[0061] In some embodiments, the thickness range of each layer structure in the imitation marble tile multi-layer co-extruded floor is as follows: UV layer is 0.13-0.17 mm, wear layer is 0.3-0.7 mm, decorative layer is 0.05-0.09 mm, first hard SPC substrate layer is 0.8-1.2 mm, foamed SPC substrate layer is 3.2-12.0 mm, second hard SPC substrate layer is 0.8-1.2 mm, and pad for sound absorption is 0.8-2.5 mm.

[0062] A method for preparing a tile-like stone-plastic floor comprises the following steps:

[0063] S1. The hard SPC substrate layer raw materials are heated and mixed; the foamed SPC substrate layer raw materials are heated and mixed;

[0064] S2. The hard SPC substrate layer raw material and the foamed SPC substrate layer raw material are transferred to the extruder;

[0065] S3. The foamed SPC substrate layer is injected into the mold through the central flow channel of the confluence core; the hard SPC substrate layer is injected into the mold through the side flow channel of the confluence core and co-extruded through a dispenser to form an upper layer of a first hard SPC substrate layer, an intermediate foamed SPC substrate layer, and a lower layer of a second hard SPC substrate layer. A rough plate;

[0066] S4. A decorative layer is provided on the first hard SPC substrate layer of the rough plate, and a wear-resistant layer is continued to be provided on the decorative layer;

[0067] S5. Coating a UV-curable transparent lacquer on the wear-resistant layer to form a UV layer;

[0068] S6. The plate passes through the plate roller and prints the pattern on the upper surface of the plate;

[0069] S7. Planing to form grooves with a beautiful seam effect. The planed part includes the UV layer, the wear-resistant layer, the decorative layer and part of the first hard SPC substrate layer. The lowest point of the planing does not exceed half the thickness of the first hard SPC substrate layer.

[0070] In some embodiments, before planing the grooves in step S7, the edges of the board need to be grooved to form a special structure that is convenient for assembly, such as a straight groove, a locking groove, etc. The locking structure is preferred.

[0071] The present application is further described below with reference to the embodiments, but is not limited thereto.

[0072] Example 1

[0073] 1. A formula for foamed multi-layer flooring:

[0074] 1.1 Hard SPC substrate layer: including the first hard SPC substrate layer and the second hard SPC substrate layer, which are equivalent to two surface layers, sandwiching the foamed SPC substrate layer (core layer) in between to form an ABA type structure.

[0075] The hard SPC substrate (surface layer) includes the following raw materials in parts by weight: 25 parts of PVC resin powder, 100 parts of heavy calcium carbonate, 3.6 parts of calcium zinc stabilizer, 3 parts of ACR processing aid, 1 part of internal lubricant, 0.8 part of external lubricant, 2.2 parts of toughening agent, 0.3 parts of carbon black, and 25 parts of silicone modified acrylic resin.

[0076] Among them, the PVC powder selected is conventional SG5 powder.

[0077] The selected calcium carbonate powder particle size is 400 mesh. Too coarse particles will cause the product to burn easily, while too fine particles will increase the cost and easily cause the product to be too brittle.

[0078] Preferably, you can also partially use ordinary SPC regrind to reduce costs and increase efficiency. Ordinary SPC regrind is the crushed material of SPC flooring, which contains some PVC resin and other ingredients. The regrind component is a "concentration" of other components.

[0079] Among them, the selected calcium zinc stabilizer is a non-toxic and environmentally friendly calcium zinc stabilizer for PVC, which is composed of zinc soap, calcium soap, auxiliary stabilizer, lubricant, etc.; it has the characteristics of non-toxicity, high efficiency, good stability, fine foam cells in products, good demoulding performance, excellent processing performance, and long production cycle.

[0080] Among them, the foaming processing aid selected is acrylic copolymer (ACR), which is copolymerized by MMA (methyl methacrylate) and acrylic esters. It can promote the plasticization performance of PVCU during processing and improve its fluidity.

[0081] Among them, the internal lubricant selected is G60, which is a lubricant whose main components include stearic acid and the like.

[0082] Among them, the toughening agent selected is modified CPVC resin particles.

[0083] The selected organosilicon-modified acrylic resin is prepared as follows:

[0084] The industrial preparation of silicone-modified epoxy acrylic resins typically involves chemical reactions and process optimization to ensure product performance stability and the feasibility of large-scale production. The following are common industrial preparation methods and their key steps:

[0085] 1) Add 70 parts of epoxy acrylic resin (as the main resin, providing mechanical strength, adhesion and curing performance), 30 parts of silicone monomer (such as γ-glycidyloxypropyltrimethoxysilane) and appropriate amounts of solvent (such as toluene, acetone, butanone, etc.) into a reactor.

[0086] A catalyst is added (for promoting the reaction between the organosilicon and the epoxy acrylic resin, such as an acidic or alkaline catalyst, preferably tetramethylammonium hydroxide).

[0087] 2) Heat the reactor to 80-100°C and stir for 4-6 hours. Monitor the viscosity (1000-50000 mPa·s (25°C)) and epoxy value of the reaction system (the epoxy value may drop to 0.2-0.4 eq / 100g after modification).

[0088] 3) Cool to below 50°C, filter to remove impurities, and add a suitable solvent (such as toluene, acetone, butanone, etc.) to adjust the viscosity (set to 1000-2000 mPa·s).

[0089] 4) Put the finished product into a sealed container and store it in a cool and dry place.

[0090] Those skilled in the art can also purchase the corresponding organosilicon-modified epoxy acrylic resin finished product as raw material.

[0091] Among them, the selected carbon black plays the role of coloring the board.

[0092] 1.2. The foamed SPC substrate layer (core layer) includes the following raw materials in parts by weight: 50 parts of PVC resin powder, 80 parts of 1250 mesh calcium carbonate, 38 parts of SPC foaming regrind, 4.5 parts of calcium zinc stabilizer, 2.5 parts of ACR processing aid, 6 parts of foaming regulator, 0.25 parts of yellow foaming agent, 0.1 parts of white foaming agent, 0.95 parts of internal lubricant, and 0.8 parts of external lubricant.

[0093] Among them, the selected PVC powder is conventional SG8 powder, because the core layer is used for foaming. The polymerization degree of SG-8 PVC resin powder is 740-650 and the K value is 59-55, which is more suitable for foaming.

[0094] The calcium carbonate powder used is 1250 mesh. When the particle size of calcium carbonate matches the foaming agent, it can act as a nucleating agent, thereby promoting foaming. The appropriate calcium carbonate particle size is less than 20μm and does not agglomerate. This allows it to better absorb the foaming gas to form bubble nuclei, control the number of cells, and make the cells finer.

[0095] a. First, calcium carbonate can act as a nucleating agent, absorbing foaming gas to form bubble nuclei, controlling the number of cells and making them finer. b. Improving melt properties: Calcium carbonate itself has high rigidity, which can slow melt deformation and mobility, thereby inhibiting excessive cell expansion. c. Controlling cell size to a finer level. When the calcium carbonate particle size is less than 20μm, it can act as a nucleating agent and promote foaming. If the calcium carbonate particle size is larger than 20μm, or too fine (e.g., less than 5μm), it will cause self-agglomeration, which will affect the foaming effect.

[0096] The SPC foam regrind used is crushed SPC foam board material. The regrind composition is "concentrated" relative to the other components. This SPC foam regrind contains residual foaming agent, which can be used. Furthermore, the SPC foam regrind itself has a relatively low density, which helps reduce the density of the foamed SPC substrate layer (core layer).

[0097] In some embodiments, the density of the foamed SPC substrate layer (core layer) is generally 1.1-1.3 g / cm 3 .

[0098] Among them, the selected calcium zinc stabilizer is a non-toxic and environmentally friendly calcium zinc stabilizer for PVC, which is composed of zinc soap, calcium soap, auxiliary stabilizer, lubricant, etc.; it has the characteristics of non-toxicity, high efficiency, good stability, fine foam cells in products, good demoulding performance, excellent processing performance, and long production cycle.

[0099] Among them, the foaming processing aid selected is acrylic copolymer (ACR), which is copolymerized by MMA and acrylic esters. It can promote the plasticization performance of PVCU during processing and improve its fluidity.

[0100] Among them, the internal lubricant selected is G60, which is a lubricant whose main components include stearic acid and the like.

[0101] Among them, the external lubricant selected is PE wax.

[0102] Among them, the foaming regulator selected is actually an acrylic ester processing aid.

[0103] The yellow foaming agent used has a gas emission of 220-230 ml / g, a decomposition temperature of 195-205° C., and a volatilization amount of ≤0.2% (110° C. for 1 hour).

[0104] The selected white foaming agent has a gas emission of 130-140 ml / g, a decomposition temperature of 157-165° C., and a volatilization amount of ≤0.5% (110° C. for 1 hour).

[0105] 2. A multi-layer co-extruded PVC floor substrate extrusion process with a beautiful seam effect, comprising the following steps:

[0106] 2.1 Prepare the hard SPC substrate layer (surface layer) and the foamed SPC substrate layer (core layer) in different kettles respectively. Specifically, according to the above formula, add calcium carbonate and PVC powder together into a high-speed mixer, then add plasticizer (such as ACR processing aid), stabilizer, lubricant and other additives, mix and stir, heat to 110-120℃, and then cool.

[0107] 2.2 Cool the mixed material from 2.1 to 65°C and put it into the storage bin. The mixed material in the storage bin is transported to the screw extruder through the spiral feeding system.

[0108] 2.3 A rigid SPC (surface layer) structural substrate was prepared using a twin-screw extruder, wherein the material formula of the surface layer was designed as described above for the surface layer extrusion. A foamed SPC (core layer) structural substrate was prepared using another single-screw extruder, wherein the material formula of the core layer was designed as described above for the core layer extrusion.

[0109] 2.4 The raw material of the foamed SPC substrate layer is injected into the mold through the central flow channel of the confluence core; the raw material of the hard SPC substrate layer is injected into the mold through the side flow channel of the confluence core, and co-extruded through a distributor to form a rough plate with the upper layer being the first hard SPC substrate layer, the middle layer being the foamed SPC substrate layer, and the lower layer being the second hard SPC substrate layer.

[0110] 2.4.1 Extrusion Section

[0111] 2.4.1.1 Equipment heating / precooling.

[0112] 2.4.1.1.1 Set the die temperature (170-180℃), mold temperature (180-190℃), and side plate temperature (190-210℃) to start

[0113] 2.4.1.1.2 Set the dispenser temperature. It is allowed and should be adjusted appropriately while ensuring stable extrusion of the product. Turn on the heating for about 0.5 hours.

[0114] 2.4.1.1.3 Set the die roller temperature (1st roller 190℃, 2nd roller 190℃, 3rd roller 180℃, 4th and 5th rollers are cold water rollers). It is allowed and should be adjusted appropriately while ensuring stable extrusion of the product. Turn on the heating for about 1.5 hours.

[0115] 2.4.1.1.4 Set the cooling roller and make sure the cooling water is flowing and the temperature is around 15℃.

[0116] 2.4.1.2 Booting

[0117] 2.4.1.2.1 Start the screw machine.

[0118] 2.4.1.2.1.1 Set the 80# auxiliary machine speed to 200R / min and the feeding speed to 120R / min.

[0119] 2.4.1.2.1.2 After the 80# auxiliary machine has discharged the material, set the 92# main machine speed to 200R / min and the feeding speed to 90R / min.

[0120] 2.4.1.2.1.3 Slowly increase the speed several times, each increase by 20-40 R / min.

[0121] 2.4.1.2.1.4 Set the stable speed, feeding speed and current. Appropriate adjustments are allowed and should be made while ensuring stable extrusion of the product.

[0122] 2.4.1.2.1.5 Taking the production of 6.5mm products as an example, set the speed of each roller as a reference.

[0123] 2.4.1.2.1.6 Reference for setting of traction, bracket and lampshade.

[0124] 2.4.1.3 Discharging pull plate.

[0125] 2.4.1.3.1 Move the machine and place the die roller close to the extrusion die to prepare for drawing the plate.

[0126] 2.4.1.3.2 After the extruded sheet comes out of the die, it is manually pulled onto the cooling and shaping rollers for transmission.

[0127] 2.4.1.3.3 After the flatness of the extruded sheet and the thickness of each layer have been adjusted and confirmed, turn on the lampshade and heat the lamination process. The film is a PVC color film, available in a variety of colors. Here, a gray stone-textured PVC color film is used. A wear-resistant layer is then applied.

[0128] 2.4.1.3.4 According to the required width of the laminated board, trim the edges by adjusting the distance between the rotary blades.

[0129] 2.4.1.3.5 After passing through the cooling zone, the film-coated boards are cut into boards of required size by shearing machines.

[0130] 2.4.1.3.6 Apply UV curing transparent paint on the wear-resistant layer of the plate to form a UV layer.

[0131] 2.4.1.3.7 The pattern is imprinted on the upper surface of the plate through the plate roller.

[0132] 2.5 slotting

[0133] 2.5.1 The edges of the panels shall be grooved as required to form a locking structure for easy assembly.

[0134] 2.5.2 Grooving (planing) is performed on the adjacent surfaces of each plate. The planing depth is designed to be 0.6-1.0mm. High-speed rotating tools are used for processing to form grooves with a beautiful seam effect.

[0135] For example, a floor that has been cut to the required size is divided into four sides: 1, 2, 3, and 4. If you mark them clockwise and plan all the sides 1 and 2, you can get grooves formed on all the adjacent sides of the floor. In this way, after splicing the floor, each side will have a beautiful seam appearance. Figure 1 and Figure 3 , Figure 1 The image shows a groove with a beautiful seam effect obtained by planing one side of the male groove. Figure 3 The image shows a groove with a beautiful seam effect obtained by planing one side of the mother groove.

[0136] In addition, grooves can be dug at other locations of the board according to the design to obtain grooves that simulate the grouting effect of ceramic tiles.

[0137] In this embodiment, the thickness of each layer of the imitation marble tile multi-layer co-extruded floor is as follows: UV layer is 0.15 mm, wear layer is 0.3 mm, decorative layer is 0.07 mm, first hard SPC substrate layer is 0.8-1.0 mm, foamed SPC substrate layer is 3.2-3.5 mm, second hard SPC substrate layer is 0.8-1.0 mm, and sound absorption pad is 1-2 mm.

[0138] 0.15mm of the UV layer, 0.3mm of the wear-resistant layer, 0.07mm of the decorative layer, and about 0.1-0.4mm of a portion of the first hard SPC substrate layer were removed by planing to form a groove with a depth of about 0.6-1.0mm to simulate the effect of beautiful seams.

[0139] The depth of planing is such that the lowest point of the groove does not exceed half of the solid first hard SPC substrate layer.

[0140] 2.5.4 The finished joints will have a marble-like appearance. The joint dimensions can be adjusted according to customer needs.

[0141] Example 2

[0142] 1. A formula for foamed multi-layer flooring with a beautiful seam effect:

[0143] The hard SPC substrate layer (surface layer) includes the following raw materials in parts by weight: 25 parts of PVC resin powder, 110 parts of heavy calcium carbonate, 3 parts of calcium zinc stabilizer, 3 parts of ACR foaming processing aid, 1 part of internal lubricant, 0.8 parts of external lubricant, 2.2 parts of toughening agent, 0.3 parts of carbon black, and 20 parts of silicone modified acrylic resin.

[0144] The foamed SPC substrate layer (core layer) includes the following raw materials in parts by weight: 45 parts of PVC resin powder, 80 parts of calcium carbonate, 40 parts of SPC foaming recycled material, 3.5 parts of calcium zinc stabilizer, 2.5 parts of ACR foaming processing aid, 0.95 parts of internal lubricant, 0.8 parts of external lubricant, 6 parts of foaming regulator, 0.25 parts of yellow foaming agent, and 0.1 parts of white foaming agent.

[0145] 2. The preparation method is the same as that in Example 1 to obtain a foamed multi-layer floor with a beautiful seam effect.

[0146] Example 3

[0147] 1. A formula for foamed multi-layer flooring with a beautiful seam effect:

[0148] The hard SPC substrate layer (surface layer) includes the following raw materials in parts by weight: 25 parts of PVC resin powder, 95 parts of heavy calcium carbonate, 3.6 parts of calcium zinc stabilizer, 3 parts of ACR foaming processing aid, 1 part of internal lubricant, 0.8 part of external lubricant, 2.2 parts of toughening agent, 0.3 parts of carbon black, and 30 parts of silicone modified acrylic resin.

[0149] The foamed SPC substrate layer (core layer) includes the following raw materials in parts by weight: 55 parts of PVC resin powder, 80 parts of calcium carbonate, 35 parts of SPC foaming recycled material, 4 parts of calcium zinc stabilizer, 2.5 parts of ACR foaming processing aid, 0.95 parts of internal lubricant, 0.8 parts of external lubricant, 6 parts of foaming regulator, 0.25 parts of yellow foaming agent, and 0.1 parts of white foaming agent.

[0150] 2. The preparation method is the same as that in Example 1 to obtain a foamed multi-layer floor with a beautiful seam effect.

[0151] Comparative Example 1

[0152] 1. Conventional floor formula:

[0153] The base material components are 75 parts of PVC resin powder, 250 parts of heavy calcium carbonate, 7 parts of stabilizer, 0.7 parts of external lubricating PE wax, and 1.7 parts of internal lubricating CA80.

[0154] Among them, the PVC powder selected is conventional SG5 powder.

[0155] Among them, the selected calcium carbonate powder is 400 mesh. Too coarse particles will cause the product to burn easily, and too fine particles will increase the cost and easily cause the product to be too brittle.

[0156] Among them, the stabilizer selected is calcium zinc stabilizer.

[0157] Among them, the internal lubricant selected is stearic acid.

[0158] Among them, the external lubricant selected is PE wax.

[0159] 2. The substrate extrusion process, its characteristics and backing film selection include the following steps:

[0160] 2.1 Add 400 mesh heavy calcium carbonate, PVC powder and part of the recycled material into a high-speed mixer, along with stabilizer and lubricant. Mix and heat to 110-120℃ and then cool.

[0161] 2.2 Cool the mixed material in 2.1 to 65°C and put it into the storage bin. The mixed material in the storage bin is transported to the twin-screw extruder (using a conical twin-screw extruder) through a spiral feeding system.

[0162] 2.3 The barrel temperature is controlled at 160-180℃, the mold temperature is controlled at 200-220℃, and the die cooling temperature is controlled at 100-140℃. After extrusion, it is formed by the mold, and the thickness is adjusted and shaped by rollers 1 and 2. Roller 3 is used to laminate the color film (stone-grained color film) and the wear-resistant layer. Rollers 4 and 5 are used for embossing (marble pattern). After cooling, the plate is cut to obtain the plate.

[0163] 2.4 Slotting

[0164] 2.4.1 Perform slotting as required for assembly.

[0165] 2.4.2 Grooving (planing) is performed on the adjacent surfaces of each sheet of plate using a high-speed rotating tool.

[0166] Because the substrate layer in this comparative example is a single layer, during the planing process, all the parts above the substrate layer are planed off, and then a small part of the substrate layer is removed. The planing depth of the substrate layer is about 0.1-0.4 mm, and a groove simulating the ceramic tile grouting effect is obtained.

[0167] Comparative Example 2

[0168] 1. Conventional cold-pasted multi-layer flooring:

[0169] The base material components are 400 parts of PVC resin powder, 1700 parts of calcium carbonate, 150 parts of DOTP oil, 7 parts of stabilizer and 3 parts of carbon black.

[0170] Among them, the PVC powder selected is conventional SG5 powder.

[0171] Among them, the calcium carbonate powder selected is 400 mesh.

[0172] Among them, the stabilizer selected is calcium zinc stabilizer.

[0173] 2. The substrate extrusion process, its characteristics and backing film selection include the following steps:

[0174] 2.1 Add 400 mesh heavy calcium carbonate and PVC powder into the internal mixer, then add stabilizer, carbon black and DOTP oil for internal mixing;

[0175] 2.2 The mixed material in 2.1 is milled and formed into an LVT substrate layer by calendering;

[0176] 2.3 Use a hot press to heat-press the wear-resistant layer, color film, and LVT substrate layer;

[0177] 2.4 Use glue to bond the semi-finished product to the purchased wood-plastic base material;

[0178] 2.5 The semi-finished product in 2.4 is again bonded to the LVT substrate layer with glue to produce a cold-laminated multi-layer floor.

[0179] 2.6 Slotting

[0180] 2.6.1 Slotting shall be performed as required for assembly.

[0181] 2.6.2 Grooving (planing) is performed on the adjacent surfaces of each sheet of plate using a high-speed rotating tool.

[0182] During the planing process, all the parts above the substrate layer are planed off, and then a small part of the substrate layer is removed. The planing depth of the substrate layer is about 0.1-0.4mm, and a groove simulating the ceramic tile grouting effect is obtained.

[0183] Test Example 1

[0184] The content of organosilicon in organosilicon-modified acrylic resin was adjusted to prepare modified acrylic resins with different organosilicon contents.

[0185] The preparation method is as follows:

[0186] 1) Add appropriate amounts of epoxy acrylic resin, organosilicon monomer (such as γ-glycidyloxypropyltrimethoxysilane), and solvent (such as toluene, acetone, or butanone) to a reaction kettle. The proportions of epoxy acrylic resin and organosilicon monomer are shown in Table 1.

[0187] The catalyst tetramethylammonium hydroxide was added.

[0188] 2) Heat the reactor to 80-100°C and stir for 4-6 hours. Monitor the viscosity (1000-50000 mPa·s (25°C)) and epoxy value of the reaction system (the epoxy value may drop to 0.2-0.4 eq / 100g after modification).

[0189] 3) Cool to below 50°C, filter to remove impurities, and add a suitable solvent (such as toluene, acetone, butanone, etc.) to adjust the viscosity (set to 1000-2000 mPa·s).

[0190] 4) Put the finished product into a sealed container and store it in a cool and dry place.

[0191] Using the prepared modified acrylic resins with different silicone contents, imitation tile stone plastic flooring was prepared using the same method as in Example 1, resulting in a tile-like stone plastic flooring with a beautiful grouting effect. Furthermore, in this test example, the width of the grouting groove was increased by further planing for use in water contact angle experiments.

[0192] The water contact angle, defined as the contact angle formed by a water droplet on a solid surface, is a commonly used indicator of the hydrophilicity or hydrophobicity of a solid surface. Water contact angle testing can be used to inspect the quality of surface coatings and evaluate the wettability of materials, and is widely used in fields such as materials science, coatings processing, and surface engineering.

[0193] Hydrophilicity and hydrophobicity: When the contact angle is less than 90°, it indicates that the material surface is hydrophilic, that is, water spreads easily on the material surface. When the contact angle is greater than 90°, it indicates that the material surface is hydrophobic, and water does not spread easily on its surface.

[0194] The results are shown in Table 1.

[0195] Table 1 Effect of silicone content on water contact angle

[0196] content blank 10％ 20％ 30％ 40％ Epoxy acrylic resin content 100 copies 90 servings 80 servings 70 servings 60 servings Silicone monomer 0 copies 10 servings 20 servings 30 servings 40 servings contact angle 52° 74° 85° 95° 97°

[0197] From the comparative data in Table 1, it can be concluded that the silicone content reaches the highest cost-effectiveness when it is 30%, and increasing it to 40% has little effect on improving the water contact angle.

[0198] Test Example 2

[0199] According to the requirements of the embodiment and the control example, a finished product was made, and the location of the beautiful seam was planed out. A comparative test of the stain resistance performance was carried out at the location of the beautiful seam and its surroundings.

[0200] (1) The stain resistance test method is as follows:

[0201] Place the specimen in a room temperature environment.

[0202] Wipe the surface of the specimen clean with absorbent cotton. Place a small amount of contaminant (e.g., 2-3 drops) on the upper surface of each of the two horizontal specimens (at and around the caulking area). Cover the contaminant on one of the specimens with a glass cover.

[0203] After 16 hours of contact time, wipe away any contaminants with a clean soft cloth, then rinse with water, then rinse with water containing a wetting agent, and finally clean the surface with ethanol and wipe dry with absorbent cotton. For panels with a textured (or embossed) surface, use a brush to remove any contaminants. After cleaning, place the specimen at room temperature for 24 hours, then place it on the test bench and observe the surface with normal vision (or corrected to normal vision) from a distance of 400 mm.

[0204] (2) Result presentation

[0205] Influence of test materials on specimen surface:

[0206] Level 5: No significant changes;

[0207] Grade 4: Slight changes in gloss and / or color;

[0208] Grade 3: Moderate changes in gloss and / or color;

[0209] Level 2: There is a noticeable change in gloss and / or color;

[0210] Level 1: Surface deformation and / or blistering.

[0211] The results are shown in Table 2.

[0212] Table 2 Comparison of anti-fouling performance of beauty seam groove

[0213] Test items Example 1 Example 2 Example 3 Comparative Example 1 Comparative Example 2 Carbon ink 4 4 4 1 1 Oil-based marker 3 3 3 1 1 Water-based red crayon 4 4 4 1 1 soy sauce 4 4 4 1 1 iodine 1 1 1 1 1

[0214] It can be seen from Table 2 that the stain resistance of the imitation tile stone plastic floor with modified materials in the seam groove area is significantly better than that of the control example.

[0215] Industrial Application Examples

[0216] The imitation tile stone plastic floor with beautiful seam effect of this application has better resistance to general pollutants than the control example. Lock-type installation has a wide range of application environments and can replace marble tiles in some scenarios, such as

[0217] 1. Home decoration scene

[0218] Including living room / bedroom, kitchen / bathroom, balcony / basement.

[0219] 2. Commercial Space

[0220] Including offices / conference rooms, shopping malls / shops, hotels / B&Bs.

[0221] 3. Public places

[0222] Including hospitals / schools, gyms / dance studios, etc.

[0223] The above is a further detailed description of the present invention and should not be considered as a limitation on the specific implementation of the present invention. For those skilled in the art, simple deductions or substitutions that do not depart from the concept of the present invention are within the scope of protection of the present invention.

Claims

1. A tile-like stone plastic floor, characterized in that: The imitation tile stone plastic floor comprises a wear-resistant layer, a decorative layer, a first hard SPC substrate layer, a foamed SPC substrate layer, and a second hard SPC substrate layer arranged from top to bottom; The components of the first hard SPC substrate layer include 12-20 wt% of polyvinyl chloride resin (PVC), 12-20 wt% of silicone modified acrylic resin, and 50-70 wt% of calcium carbonate; The imitation tile stone plastic floor is provided with grooves from top to bottom, wherein the lowest point of the grooves does not exceed half the thickness of the first hard SPC substrate layer; the grooves are used to simulate the beautiful seam effect of tiles.

2. The imitation tile stone plastic floor according to claim 1, characterized in that: The second hard SPC substrate layer comprises 12-20 wt % of polyvinyl chloride resin (PVC), 12-20 wt % of organosilicon-modified acrylic resin, and 50-70 wt % of calcium carbonate.

3. The imitation tile stone plastic floor according to claim 1 or 2, characterized in that: The first hard SPC substrate layer and the second hard SPC substrate layer include the following raw materials in parts by weight: 20-30 parts of polyvinyl chloride resin (PVC), 80-110 parts of calcium carbonate, 2-4 parts of calcium zinc stabilizer, 2-4 parts of acrylate copolymer (ACR), 2-4 parts of toughening agent, 0.5-3 parts of internal lubricant, 0.5-3 parts of external lubricant, 0.1-0.5 parts of carbon black, and 20-30 parts of silicone modified acrylic resin.

4. The imitation tile stone plastic floor according to any one of claims 1 to 3, characterized in that: The raw materials for preparing the organosilicon-modified acrylic resin include organosilicon monomer and epoxy acrylic resin, wherein the organosilicon monomer accounts for 10%-50%, preferably 20-40%, and more preferably 30%-40% of the total mass of the organosilicon monomer and epoxy acrylic resin; and / or the viscosity of the organosilicon-modified acrylic resin is 1000-2000 mPa·s.

5. The imitation tile stone plastic floor according to claim 1, characterized in that: The texture of the decorative layer includes at least one of wood texture, marble texture, granite texture, cloth texture, carpet texture, cement texture, and metal texture; preferably, marble texture.

6. The imitation tile stone plastic floor according to claim 1, characterized in that: The foamed SPC substrate layer includes the following raw materials in parts by weight: 40-60 parts of polyvinyl chloride resin (PVC), 70-100 parts of calcium carbonate, 30-60 parts of SPC foaming recycled material, 3-5 parts of calcium zinc stabilizer, 1-3 parts of acrylate copolymer (ACR), 5-10 parts of foaming regulator, 0.1-0.5 parts of yellow foaming agent, 0.1-0.3 parts of white foaming agent, 0.5-3 parts of internal lubricant, and 0.5-3 parts of external lubricant.

7. The imitation tile stone plastic floor according to claim 1, characterized in that: A UV layer is provided above the wear-resistant layer; and / or a sound-absorbing layer is provided below the second hard SPC substrate layer.

8. The imitation tile stone plastic floor according to any one of claims 1 to 3, characterized in that: The thickness of the first hard SPC substrate layer is 0.8-1.2 mm, the thickness of the foamed SPC substrate layer is 3.2-12.0 mm, and the thickness of the second hard SPC substrate layer is 0.8-1.2 mm; and / or, the first hard SPC substrate layer, the foamed SPC substrate layer and the second hard SPC substrate layer are prepared by a co-extrusion process.

9. The imitation tile stone plastic floor according to any one of claims 1 to 4, characterized in that: The grooves are formed by planing.

10. A method for preparing a tile-like stone plastic floor, characterized in that: The following steps are involved: S1. The hard SPC substrate layer raw materials are heated and mixed; the foamed SPC substrate layer raw materials are heated and mixed; S2. The hard SPC substrate layer raw material and the foamed SPC substrate layer raw material are transferred to the extruder; S3. The foamed SPC substrate layer is injected into the mold through the central flow channel of the confluence core; the hard SPC substrate layer is injected into the mold through the side flow channel of the confluence core and co-extruded through a dispenser to form an upper layer of a first hard SPC substrate layer, an intermediate foamed SPC substrate layer, and a lower layer of a second hard SPC substrate layer. A rough plate; S4. A decorative layer is provided on the first hard SPC substrate layer of the rough plate, and a wear-resistant layer is continued to be provided on the decorative layer; S5. Coating a UV-curable transparent lacquer on the wear-resistant layer to form a UV layer; S6. The plate passes through the plate roller and prints the pattern on the upper surface of the plate; S7. Planing to form grooves with a beautiful seam effect. The planed part includes the UV layer, the wear-resistant layer, the decorative layer and part of the first hard SPC substrate layer. The lowest point of the planing does not exceed half the thickness of the first hard SPC substrate layer.

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