Ultra-silence new material floor

Abstract

The invention belongs to the technical field of silence floor processing, and particularly relates to an ultra-silence new material floor which comprises a transparent sheet layer, a color film layer, an LVT large skin layer, a micropore structure layer, a bearing layer and a ground mat layer which are sequentially arranged from top to bottom. The LVT large skin layer comprises a dense layer and a micro-foaming layer, the dense layer and the micro-foaming layer are processed by adopting a co-extrusion foaming production process, the defects in the prior art are overcome, and through the co-extrusion micro-foaming layer, sound generated by foot treading can be effectively absorbed and blocked, noise transmission is greatly reduced, and a quiet indoor environment is created for a user. Compared with a common ultra-silence floor, noise can be reduced by 5-10 decibels, and quietness and comfort are truly achieved.

Description

Technical Field

[0001] The invention belongs to the technical field of silent floor processing, and in particular relates to a super silent new material floor. Background Art

[0002] Ultra-quiet flooring is gaining popularity in the current flooring market, attracting widespread consumer interest. Existing ultra-quiet flooring utilizes a variety of technologies to achieve its quieting effect. Some products incorporate special quieting components within the base material, such as LVT sheets that create a vacuum chamber inside. This cushions and absorbs the sound and impact of footsteps. Other products incorporate a damping and sound-insulating felt layer on the back of the floor to further reduce noise transmission. Furthermore, products like cork flooring, due to their unique airbag structure, possess inherent elasticity and cushioning properties, effectively blocking out passing noise.

[0003] However, existing ultra-quiet flooring still has certain limitations. For example, some products lack moisture resistance, especially in locations with high humidity or significant humidity fluctuations, such as near walls, under window sills, at doorways, and on lower floors. Moisture can easily affect the floor's service life. Furthermore, the antimicrobial properties of some products rely on a single antimicrobial agent, and their effectiveness needs to be improved. In terms of structure and production process, some traditional ultra-quiet flooring also faces challenges in maintaining stability and durability in complex operating environments.

[0004] Therefore, it is necessary to develop a new silent floor to meet market demand. Summary of the Invention

[0005] The present invention aims to provide a new ultra-quiet flooring material that overcomes the shortcomings of existing technologies. Through a co-extruded micro-foam layer, it effectively absorbs and blocks footsteps, significantly reducing noise transmission and creating a quiet indoor environment. Compared to conventional ultra-quiet flooring, it can reduce noise by 5 to 10 decibels, providing true quietness and comfort.

[0006] In order to solve the above problems, the technical solutions adopted by the present invention are as follows: An ultra-quiet new material floor comprises a transparent sheet layer, a color film layer, an LVT large cortex layer, a microporous structure layer, a bearing layer and a floor cushion layer, wherein the transparent sheet layer, the color film layer, the LVT large cortex layer, the microporous structure layer, the bearing layer and the floor cushion layer are arranged in sequence from top to bottom.

[0007] Preferably, the floor mat material is IXPE or XPE or HDPE or PP or cork or EVA or PE or rubber.

[0008] Preferably, the LVT large skin layer includes a dense layer and a micro-foam layer, and the dense layer and the micro-foam layer are processed by a co-extrusion foaming production process.

[0009] Preferably, the raw material formula of the dense layer includes 100 parts of PVC resin, 60-80 parts of calcium carbonate or filler, 30-40 parts of plasticizer, and 3-5 parts of stabilizer.

[0010] Preferably, the raw material formula of the micro-foam layer is: 100 parts of PVC resin, 1-4 parts of foaming agent, 30-60 parts of calcium carbonate or filler, 20-30 parts of plasticizer, and 3-5 parts of stabilizer.

[0011] Preferably, the co-extrusion foaming production process comprises the following steps: S1: Extrusion of the dense layer: feeding the dense layer raw material into the first extruder, extruding it from the die after melting and plasticizing to form a dense layer billet, controlling the extrusion speed and thickness of the dense layer so that its density reaches 1.6 to 2.2; S2: Extrusion of the lower micro-foam layer: Simultaneously, the micro-foam layer raw material is fed into a second extruder. After the raw material is melted and plasticized, it is combined with the dense layer blank through a co-extrusion die. During the extrusion process, the foaming agent is heated and decomposed to produce gas, forming a micro-foam structure. The extrusion parameters of the micro-foam layer are controlled to achieve a density of 0.7-1.6. S3: Composite cooling: The co-extruded LVT base material passes through a cooling roller group for cooling and shaping. The cooling temperature is controlled at 20-40°C to ensure that the two-layer structure is tightly bonded. S4: Traction cutting: The cooled LVT base material is pulled by the traction machine at a stable speed and cut into sheets of a certain length according to production requirements to form LVT sheets; S5: Surface treatment: Polish and clean the surface of the LVT sheet to obtain the LVT leather, in preparation for the subsequent lamination of the transparent sheet layer and the color film layer.

[0012] Preferably, the transparent sheet is coated with an environmentally friendly adhesive on the surface of the processed LVT leather, the transparent sheet is attached, and compacted by a roller pressing device. The color film layer is also coated with an adhesive on the surface of the transparent sheet, the color film layer is attached, and rolled and compacted again.

[0013] Preferably, a UV layer is further provided on the LVT skin. The UV layer is formed by coating a UV coating on the surface of the LVT sheet in step S4 and curing it through a UV curing device. The curing time is 10 to 30 seconds and the ultraviolet intensity is 800 to 1200 mJ / cm². The UV layer is then placed in a heat treatment furnace with the temperature set at 80 to 120°C and the treatment time being 10 to 20 minutes to improve the physical properties and surface hardness of the sheet.

[0014] Preferably, the microporous structure layer, the load-bearing layer, and the underlay layer are laminated in the order of the floor structure, with the microporous structure layer, the load-bearing layer, and the underlay layer laminated sequentially beneath the LVT skin. Each layer is laminated using a suitable adhesive and is securely bonded by hot or cold pressing. The hot pressing process is controlled at a temperature of 100-150°C, a pressure of 0.5-1.0 MPa, and a time adjusted according to the layer thickness.

[0015] Preferably, the filler is a biomass material, which is wood powder, bamboo powder or other biomass fibers, and is dried to control the moisture content to be below 5%.

[0016] Preferably, the material of the bearing layer is a mixture of one or more of wood-plastic material, SPC material, LSPC material, non-PVC material, and MGO material.

[0017] Compared with the prior art, the present invention has the following beneficial effects: 1. Superior Quietness: Through innovative structural design, a microporous structure layer is specially placed beneath the dense layer. The co-extruded micro-foam layer effectively absorbs and blocks the sound of footsteps, significantly reducing noise transmission and creating a quiet indoor environment for users. Compared with ordinary ultra-quiet flooring, it can reduce noise by 5-10 decibels, truly achieving quiet and comfortable.

[0018] 2. Excellent environmental performance: The use of a large amount of biomass materials, such as wood flour and bamboo powder, are all renewable resources, reducing dependence on non-renewable resources. During the production process, no harmful substances such as formaldehyde are added, ensuring indoor air quality from the source and protecting the health of users.

[0019] 3. Excellent structural stability: The seven-layer composite structure design ensures that each layer of material fits tightly together and works in synergy. From the upper UV layer to the lower underlayment layer, each layer has been carefully selected and designed, giving the floor excellent compression and bending resistance, making it less prone to deformation and extending the service life of the floor.

[0020] 4. Personalized decorative effect: A color film layer is set in the middle to provide a rich variety of colors and textures. Whether it is imitation wood grain, stone grain or other personalized patterns, it can meet the needs of different users for interior decoration styles and easily achieve the perfect combination of beauty and practicality.

[0021] 5. Good waterproof and moisture-proof properties: The load-bearing layer in the multi-layer structure and the special co-extrusion process make the floor have good waterproof and moisture-proof properties. Even in humid environments, such as bathrooms, kitchens and other areas, it can maintain stable performance and is not easily deformed by moisture. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1This is a structural diagram of a new ultra-quiet material floor. DETAILED DESCRIPTION

[0023] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention. Example

[0024] The ultra-quiet new material floor comprises, from top to bottom, a transparent sheet layer 1, a color film layer 2, an LVT large cortex layer 4, a microporous structure layer 5, a bearing layer 6, and a ground cushion layer 7.

[0025] A UV layer 3 may be provided between the color filter layer 2 and the LVT large cortex layer 4 .

[0026] Preferably, the floor mat material is IXPE or XPE or HDPE or PP or cork or EVA or PE or rubber Preferably, the material of the bearing layer is a mixture of one or more of wood-plastic material, SPC material, LSPC material, non-PVC material, and MGO material. Example

[0027] Co-extrusion foaming to produce upper LVT leather (1) Raw material preparation 1. Biomass materials: Prepare wood powder, bamboo powder and other biomass fibers according to the formula, dry them and control the moisture content below 5%.

[0028] 2. Resin Raw Materials: Select polyvinyl chloride (PVC) resin as the base material and prepare different raw material formulas for the dense layer and micro-foam layer. The dense layer raw material formula includes 100 parts PVC resin, 60-80 parts calcium carbonate or filler, 30-40 parts plasticizer, and 3-5 parts stabilizer. The micro-foam layer raw material formula includes 100 parts PVC resin, 1-4 parts foaming agent, 30-60 parts calcium carbonate or filler, 20-30 parts plasticizer, and 3-5 parts stabilizer.

[0029] (2) Debugging of co-extrusion foaming production line 1. Check all components of the co-extrusion equipment, including the extruder, mold, cooling system, etc., to ensure that the equipment is operating normally. Set the extruder temperature: the temperature of the dense layer extruder is set to 160-190℃, and the temperature of the micro-foam layer extruder is set to 150-180℃. Fine-tune according to the characteristics of the raw materials and production conditions.

[0030] (3) Online co-extrusion production of LVT base material 1. Extrusion of upper dense layer: The raw materials of dense layer are put into the first extruder, and after being melted and plasticized, they are extruded from the die to form dense layer billet. The extrusion speed and thickness of the dense layer are controlled to make its density reach 1.6-2.2 (the proportion of fillers such as calcium carbonate in the formula can be adjusted to adjust the density according to customer needs).

[0031] 2. Extrusion of the lower micro-foam layer: Simultaneously, the micro-foam layer raw material is fed into a second extruder. After the raw material is melted and plasticized, it is combined with the dense layer blank through a co-extrusion die. During the extrusion process, the foaming agent is heated and decomposed to produce gas, forming a micro-foam structure. The extrusion parameters of the micro-foam layer are controlled to achieve a density of 0.7 to 1.6.

[0032] 3. Composite cooling: The co-extruded LVT base material is cooled and shaped by a cooling roller group. The cooling temperature is controlled at 20-40°C to ensure that the two-layer structure is tightly combined.

[0033] (IV) Subsequent processing 1. Traction cutting: The cooled LVT leather is pulled by a traction machine at a stable speed and cut into sheets of a certain length according to production requirements.

[0034] 2. Surface treatment: Polish and clean the surface of the LVT leather to prepare for the subsequent lamination of the transparent sheet layer and the color film layer.

[0035] (5) Lamination of each layer 1. Laminating the transparent sheet: Apply environmentally friendly adhesive on the surface of the processed LVT leather, laminate the transparent sheet, and compact it with a roller to ensure a tight fit without bubbles.

[0036] 2. Laminating the color film layer: Apply adhesive to the surface of the transparent sheet, laminate the color film layer, and roll and compact it again.

[0037] 3. Laminating the Microporous Structure Layer, Bearing Layer, and Underlay Layer: Following the flooring structure, laminate the Microporous Structure Layer, Bearing Layer, and Underlay Layer underneath the LVT skin. Use appropriate adhesive for each layer and perform hot or cold pressing to ensure a secure bond. The hot pressing process should be maintained at a temperature of 100-150°C, a pressure of 0.5-1.0 MPa, and the time should be adjusted according to the thickness of the layer. Example

[0038] Extrusion process combined with scraping and foaming The LVT sheet was produced according to the steps of Example 2.

[0039] (3) UV-heat treatment 1. Apply UV coating on the surface of LVT sheet and cure it through UV curing equipment. The curing time is 10 to 30 seconds and the UV intensity is 800 to 1200 mJ / cm² to form a UV layer.

[0040] 2. Heat treatment: Place the UV-coated LVT sheet in a heat treatment furnace, set the temperature to 80-120°C, and treat for 10-20 minutes to improve the physical properties and surface hardness of the sheet.

[0041] (5) Subsequent bonding process 1. Laminating the color film layer: Apply adhesive on the surface of the UV layer, laminate the color film layer, and roll compaction.

[0042] 2. Lamination with the microporous structure layer, bearing layer, and ground cushion layer: Use the same lamination process as Plan 1 to ensure that each layer is tightly bonded.

[0043] 1. Thickness detection of each layer: Use a thickness gauge to detect the thickness of each layer of material to ensure that it meets the design requirements and the deviation is controlled within ±5%.

[0044] 2. Density detection: Use a densitometer to measure the density of the dense layer and the micro-foam layer respectively to ensure that the density of the dense layer is between 1.6 and 2.2, the density of the micro-foam layer in scheme 1 is between 0.7 and 1.6, and the density of the micro-foam layer in scheme 2 is between 0.5 and 1.6.

[0045] 3. Lamination quality inspection: Observe whether there are bubbles, peeling, etc. between the layers, and ensure that the bonding strength meets the standards through peel strength test.

[0046] Quiet performance test: The processed floor samples are subjected to a quiet test to detect the decibels of noise generated when walking to ensure that the ultra-quiet design requirements are met.

[0047] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above and that the invention can be embodied in other specific forms without departing from the spirit or essential characteristics of the invention. Therefore, the embodiments should be considered in all respects as illustrative and non-restrictive, and the scope of the invention is defined by the appended claims, not the foregoing description, and all variations within the meaning and range of equivalents of the claims are intended to be included therein. Any reference sign in a claim should not be construed as limiting the claim to which it relates.

Claims

1. A super-quiet new material floor, characterized by: It includes a transparent sheet layer, a color film layer, an LVT large skin layer, a microporous structure layer, a bearing layer and a ground cushion layer. The transparent sheet layer, the color film layer, the LVT large skin layer, the microporous structure layer, the bearing layer and the ground cushion layer are arranged in sequence from top to bottom. The LVT large skin layer includes a dense layer and a micro-foam layer, and the dense layer and the micro-foam layer are processed by a co-extrusion foaming production process.

2. The ultra-quiet new material floor according to claim 1, characterized in that: The floor mat material is IXPE, XPE, HDPE, PP, cork, EVA, PE or rubber.

3. The ultra-quiet new material floor according to claim 1, characterized in that: The raw material formula of the dense layer includes 100 parts of PVC resin, 60-80 parts of calcium carbonate or filler, 30-40 parts of plasticizer and 3-5 parts of stabilizer.

4. The ultra-quiet new material floor according to claim 3, characterized in that: The raw material formula of the micro-foaming layer is as follows: 100 parts of PVC resin, 1 to 4 parts of foaming agent, 30 to 60 parts of calcium carbonate or filler, 20 to 30 parts of plasticizer, and 3 to 5 parts of stabilizer.

5. The ultra-quiet new material floor according to claim 4, characterized in that: The co-extrusion foaming production process comprises the following steps: S1: Extrusion of the dense layer: feeding the dense layer raw material into the first extruder, extruding it from the die after melting and plasticizing to form a dense layer billet, controlling the extrusion speed and thickness of the dense layer so that its density reaches 1.6 to 2.2; S2: Extrusion of the lower micro-foam layer: Simultaneously, the micro-foam layer raw material is fed into a second extruder. After the raw material is melted and plasticized, it is combined with the dense layer blank through a co-extrusion die. During the extrusion process, the foaming agent is heated and decomposed to produce gas, forming a micro-foam structure. The extrusion parameters of the micro-foam layer are controlled to achieve a density of 0.7-1.

6. S3: Composite cooling: The co-extruded LVT base material passes through a cooling roller group for cooling and shaping. The cooling temperature is controlled at 20-40°C to ensure that the two-layer structure is tightly bonded. S4: Traction cutting: The cooled LVT base material is pulled by the traction machine at a stable speed and cut into sheets of a certain length according to production requirements to form LVT sheets; S5: Surface treatment: Polish and clean the surface of the LVT sheet to obtain the LVT leather, in preparation for the subsequent lamination of the transparent sheet layer and the color film layer.

6. The ultra-quiet new material floor according to claim 5, characterized in that: The transparent sheet layer is prepared by coating an environmentally friendly adhesive on the surface of the processed LVT leather, laminating the transparent sheet layer, and compacting it through a roller pressing device. The color film layer is prepared by also coating an adhesive on the surface of the transparent sheet layer, laminating the color film layer, and rolling and compacting it again.

7. The ultra-quiet new material floor according to claim 5, characterized in that: The LVT skin is also provided with a UV layer. The UV layer is formed by coating a UV coating on the surface of the LVT sheet in step S4 and curing it through a UV curing device. The curing time is 10 to 30 seconds and the ultraviolet intensity is 800 to 1200 mJ / cm². The UV layer is then placed in a heat treatment furnace with a temperature set at 80 to 120°C and a treatment time of 10 to 20 minutes to improve the physical properties and surface hardness of the sheet.

8. The ultra-quiet new material floor according to any one of claims 6 or 7, characterized in that: The microporous structure layer, load-bearing layer, and underlayment layer are laminated sequentially under the LVT skin in the order of the floor structure. Each layer is laminated using a suitable adhesive and is securely bonded through hot or cold pressing. The hot pressing process is controlled at a temperature of 100-150°C, a pressure of 0.5-1.0 MPa, and the time is adjusted according to the thickness of the layer.

9. The ultra-quiet new material floor according to claim 4, characterized in that: The filler is a biomass material, which is wood powder, bamboo powder or other biomass fibers, and is dried and has a moisture content of less than 5%.

10. The ultra-quiet new material floor according to claim 4, characterized in that: The material of the bearing layer is a mixture of one or more of wood-plastic material, SPC material, LSPC material, non-PVC material, and MGO material.

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