Ageing-suitable shock-absorbing sound-absorbing wood composite floor and preparation method thereof

Abstract

The invention discloses a damping and sound-absorbing wood composite floor suitable for aging, which is strictly and orderly compounded according to a four-layer structure from top to bottom, and all layers are clear in division of labor and have a synergistic effect to form an organic whole with complementary functions: the first layer is a wood grain facing layer; the second layer is a cushioning layer; the third layer is a wood core layer; the fourth layer is a sound absorption layer; the preparation method of the damping and sound-absorbing wood composite floor suitable for aging comprises the following steps that firstly, all the layers are evenly coated with waterborne polyurethane environment-friendly adhesives through high-precision gluing equipment, and the gluing amount is 120-150 g / m < 2 >; 2, hot-pressing compounding: during hot-pressing compounding, controlling the temperature to be 120-140 DEG C, the pressure to be 8-12MPa, the time to be 8-10 minutes and the peel strength to be greater than or equal to 1.5 N / mm, and meanwhile, avoiding the performance degradation of the material caused by high temperature; the invention has the following beneficial effects: the noise within the frequency range of 100-5000 Hz is comprehensively reduced to 35-45 decibels; a weight of 60kg freely falls down at a height of 30cm, and the impact absorption value of the floor reaches 55-60%; a 24-hour boiling water dipping test shows that the water absorption thickness swelling rate is less than or equal to 8%; and the cost is reduced by 30-40%.

Description

Technical Field

[0001] The present invention relates to the technical field of building decoration materials, and specifically to an aging-friendly shock-absorbing and sound-absorbing wood composite floor and a preparation method thereof. The wood composite floor is particularly suitable for elderly living environments with high requirements for safety, comfort and noise control, such as nursing homes, elderly apartments and home aging-friendly renovation scenarios. Background Art

[0002] As the global aging process accelerates, the elderly population's demand for a safe and comfortable living environment is becoming increasingly prominent. Existing wooden flooring products have significant functional deficiencies: (1) Insufficient shock absorption performance: Traditional wooden floors are mostly single-layer or simple composite structures with limited shock absorption capacity. Elderly people are relatively slow in movement and have weak balance ability. When they fall, the floor lacks sufficient shock absorption, which can easily cause serious injuries such as fractures. According to statistics, among accidents involving elderly people at home, injuries caused by poor floor shock absorption account for more than 30%; (2) Poor sound absorption: Ordinary wooden floors have insufficient ability to suppress the conduction of noise such as footsteps and furniture movement, and are difficult to effectively block external noise (such as voices downstairs and traffic noise). Studies have shown that indoor walking noise under traditional wooden floors can reach 60-70 decibels, seriously affecting the rest and quality of life of the elderly. (3) Lack of targeted design: Existing floors do not fully consider the needs of aging. For example, they do not combine acoustic principles to optimize the structure to improve sound absorption performance, and do not consider both environmental protection and durability in the selection of materials. Some floors with only shock absorption or sound absorption functions often have a short service life or high cost due to unreasonable structural design, making them difficult to promote. The current market is in urgent need of an innovative floor product and its preparation method that deeply integrates shock absorption, sound absorption and aging-friendly needs. The present invention is designed to fill this gap and overcome the shortcomings of the existing technology. Summary of the Invention

[0003] The purpose of the present invention is to provide an aging-friendly, shock-absorbing and sound-absorbing wood composite floor and its preparation method that integrates the characteristics of high-efficiency shock absorption, excellent sound absorption, environmental protection and durability, so as to comprehensively improve the safety, quietness and comfort of the living environment for the elderly, while ensuring structural stability and long service life to meet actual application needs.

[0004] To achieve the above objectives, the present invention provides the following technical solution: an aging-friendly, shock-absorbing, and sound-absorbing wood composite flooring, which is constructed in a strictly ordered four-layer structure from top to bottom, with each layer having a clear division of labor and synergistic effects, forming an organic whole with complementary functions: First layer: Wood grain finish layer—made from high-quality solid wood veneer (thickness 0.6-4.0mm) or LVT (vinyl laminate flooring, thickness 1.0-4.0mm). Solid wood veneer retains the natural wood grain, creating a warm and natural living atmosphere and providing a skin-friendly feel, which meets the elderly's preference for natural materials. LVT offers enhanced wear resistance and water resistance, making it easy to clean and maintain, making it suitable for special areas such as bathrooms and kitchens. This layer also features an anti-slip treatment (friction coefficient of 0.6-0.8), effectively reducing the risk of slips for the elderly. The second layer: the shock-absorbing layer—made of IXPE (cross-linked polyethylene foam), with a thickness of 1.0-4.0 mm. IXPE is made through chemical cross-linking and physical foaming processes, resulting in a unique closed-cell structure that imparts high elasticity (compression rebound rate > 90%), aging resistance (service life exceeding 15 years), and excellent cushioning properties. Experimental testing has shown that this layer can attenuate the impact force of a 50cm free fall by over 60%, significantly reducing the severity of falls in the elderly. IXPE is also environmentally friendly and non-toxic, complying with the GB18586-2001 standard, "Limits of Hazardous Substances in Polyvinyl Chloride Coil Flooring for Interior Decoration and Renovation," ensuring safety. The third layer: wooden core layer - uses solid wood multi-layer boards with a thickness of 8-15mm. It is made of an odd number of layers of veneer that are crisscrossed and hot-pressed. It has a stable structure, a static bending strength of ≥35MPa, and an elastic modulus of ≥4000MPa. It overcomes the defects of traditional single-layer wood boards that are prone to warping and deformation. The back is provided with sound-absorbing grooves according to precise parameters. The grooves are 4-10mm deep, 2.0-4.5mm wide, and 15-50mm apart. They are arranged in a regular matrix. This design is based on the principle of Holm-Hertz resonance cavity: when external sound waves are transmitted into the grooves, the air column in the cavity vibrates, and friction with the cavity wall consumes sound energy, achieving efficient absorption of noise of specific frequencies (for example, it can reduce low-frequency noise of 100-800Hz by 15-20dB). The fourth layer: sound-absorbing layer - uses a foamed sound-absorbing material with a thickness of 1.5-5.0mm (such as polyurethane foam material). Its internal porosity reaches 80%-90%, and the pore size distribution is uniform (10-50μm). After the sound waves enter the material, they are reflected and refracted multiple times in the pores, and the friction with the pore walls is converted into heat energy and dissipated. It has a significant absorption effect on medium and high frequency noise (800-5000Hz) (reducing 20-30 decibels), and forms a dual sound-absorbing system with full coverage of "low frequency-medium and high frequency" with the sound-absorbing grooves of the wooden core layer.

[0005] Preferably, the edges of the aging-friendly shock-absorbing and sound-absorbing wood composite floor are connected by locking slots.

[0006] The method for preparing the age-friendly, vibration-absorbing, and sound-absorbing wood composite flooring comprises the following steps: 1. applying an environmentally friendly water-based polyurethane adhesive (formaldehyde emission ≤ 0.05 mg / m³, in compliance with GB18583-2008) between the layers, and uniformly coating the adhesive using high-precision adhesive coating equipment (applying an adhesive amount of 120-150 g / m²); 2. performing hot-press lamination, wherein the temperature is controlled at 120-140°C, the pressure is 8-12 MPa, and the duration is 8-10 minutes to ensure strong interlayer adhesion (peel strength ≥ 1.5 N / mm) while preventing degradation of material properties due to high temperatures.

[0007] Compared with the prior art, the present invention provides an aging-friendly, shock-absorbing, and sound-absorbing wood composite floor and a preparation method thereof, which has the following beneficial effects: (1) Innovation of dual sound absorption system Combining the sound-absorbing grooves of the wood core (utilizing the Holm-Hertz resonance effect) with the sound-absorbing principle of the porous material in the sound-absorbing layer, this floor has been tested to reduce noise by 35-45 decibels in the frequency range of 100-5000Hz, more than double the effect of traditional single-structure flooring (which only reduces 15-20 decibels). (2) Deep integration of aging-friendly functions The IXPE shock-absorbing layer, combined with the anti-slip treatment of the wood-grain finish, provides comprehensive safety protection. In simulation experiments, the floor's impact absorption value for a 60kg object dropped freely from a height of 30cm reached 55%-60% (far exceeding the national standard requirement of ≥45%), effectively protecting the mobility of the elderly. Furthermore, the material is environmentally friendly and non-toxic, meeting the needs of the elderly for a healthy living environment. (3) Structural performance optimization The solid wood multi-layer core layer gives the floor excellent structural stability. After a 24-hour boiling water immersion test, the water absorption thickness expansion rate is ≤8%, ensuring that it is not easily deformed in different temperature and humidity environments (temperature -10℃-40℃, humidity 40%-80%), extending the service life to more than 20 years and reducing replacement costs. (4) Balance between environmental protection and economic efficiency Environmentally friendly materials and processes are selected, and the adhesives, IXPE and foam materials all comply with relevant national environmental protection standards; the production process is mature and can be produced on a large scale. Compared with similar imported aging-friendly floors, the cost is reduced by 30%-40%, and it has good market promotion potential. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The accompanying drawings are used to provide a further understanding of the present invention and constitute a part of the specification. Together with the embodiments of the present invention, they are used to explain the present invention and do not constitute a limitation of the present invention. In the accompanying drawings: Figure 1 This is a schematic structural diagram of an aging-friendly, shock-absorbing, and sound-absorbing wood composite floor proposed by the present invention; Figure 2 This is a schematic diagram of the cross-sectional structure of the wood core layer of an aging-friendly, shock-absorbing, and sound-absorbing wood composite flooring proposed by the present invention; Figure 3 This is the first page of the test report for the aging-friendly, shock-absorbing, and sound-absorbing wood composite flooring proposed by the present invention; Figure 4 The second page of the test report for the aging-friendly, shock-absorbing, and sound-absorbing wood composite flooring proposed by the present invention; Figure 5 The third page of the test report of the aging-friendly, shock-absorbing, and sound-absorbing wood composite floor proposed by the present invention; In the figure: 1. Wood grain finishing layer; 2. Shock-absorbing layer; 3. Wooden core layer; 4. Sound-absorbing layer. DETAILED DESCRIPTION

[0009] The technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only 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 ordinary technicians in this field without making creative work are within the scope of protection of the present invention. Example

[0010] See also Figure 1-5 The present invention provides a technical solution: an aging-friendly, shock-absorbing, and sound-absorbing wood composite floor, which is strictly laminated in a four-layer structure from top to bottom, with each layer having a clear division of labor and synergistic effects, forming an organic whole with complementary functions: First layer: Wood grain finish layer 1: Select 1.0mm thick oak solid wood veneer, tested for wear resistance of ≥6000 revolutions and formaldehyde emission of ≤0.03mg / m³. The solid wood veneer retains the natural wood texture, creating a warm and natural living atmosphere visually, and is skin-friendly to the touch, meeting the psychological preference of the elderly for natural materials; Second layer: Shock-absorbing layer 2: 3.5mm thick IXPE (cross-linked polyethylene foam material) is purchased. Testing shows a compression rebound rate of ≥92%, environmental protection indicators, and heavy metal content that meets the GB6675.4-2014 standard. IXPE is made through chemical cross-linking and physical foaming processes, with a unique closed-cell structure that makes it highly elastic and aging-resistant, with a service life of over 15 years and excellent cushioning performance. Third layer: Wood core layer 3: Customized 10mm thick solid wood multilayer board (7-layer structure), which is made of an odd number of layers of veneer crisscrossed and hot-pressed. It has a stable structure, static bending strength ≥38MPa, and elastic modulus ≥4000MPa, overcoming the defects of traditional single-layer wood boards that are prone to warping and deformation. The back is provided with sound-absorbing grooves according to precise parameters. The grooves are 4.5mm deep, 3.0mm wide, and 15mm apart, arranged in a regular matrix. Based on the Holm-Hertz resonance cavity principle: when external sound waves are transmitted into the grooves, the air column in the cavity vibrates, and friction with the cavity wall consumes sound energy, achieving efficient absorption of noise of specific frequencies; The fourth layer: Sound-absorbing layer 4: 2.0mm thick polyurethane foam material is selected, with a porosity of ≥85% and a sound absorption coefficient of ≥0.7 at a frequency of 1000Hz; its internal porosity reaches 80%-90%, and the pore size distribution is uniform (10-50μm). After the sound waves enter the material, they are reflected and refracted multiple times in the pores, and the friction with the pore walls is converted into heat energy and dissipated. It has a significant absorption effect on medium and high frequency noise (800-5000Hz) (reduced by 20-30 decibels), and forms a dual sound absorption system with full coverage of "low frequency-medium and high frequency" with the sound-absorbing grooves of the wooden core layer.

[0011] Furthermore, the edges of the aging-friendly shock-absorbing and sound-absorbing wood composite floor are connected by locking slots.

[0012] The preparation method of the aging-friendly shock-absorbing and sound-absorbing wood composite floor comprises the following steps: 1. Gluing: Evenly apply water-based polyurethane adhesive on the back of the solid wood veneer using a roller coater, and control the glue application amount to 130g / ㎡; 2. Hot pressing: put the glued wood grain finishing layer 1 and IXPE cushioning layer 2 into a hot press at a temperature of 130°C and a pressure of 10 MPa for 8 minutes to form a composite unit of wood grain finishing layer 1 and cushioning layer 2; 3. Apply glue on the other side of IXPE, with a glue amount of 140g / ㎡, and hot press it with the wooden core layer 3, using the same hot pressing conditions as above; Fourth, apply glue on the back of the wooden core layer 3 at a rate of 120g / m2, and hot press it with the sound-absorbing layer 4 under the same hot pressing conditions as above to form a complete floor.

[0013] (3) Finished product inspection and acceptance Shock absorption performance: Impact absorption test is carried out in accordance with GB / T15102-2017 "Impregnated Paper Laminated Wood Flooring", and the impact absorption value is required to be ≥55%; Sound absorption performance: tested using the reverberation chamber method (GB / T20247-2006), the average sound absorption coefficient in the frequency range of 100-5000Hz is ≥0.5; Environmental indicators: Formaldehyde emission is tested according to GB18580-2017 (≤0.05mg / m³) to ensure that no harmful substances exceed the standard; Appearance and structure: Check whether the floor surface is flat and crack-free, whether the interlayer bonding is firm (peel strength test ≥1.5N / mm), and whether the size of the sound-absorbing groove meets the design requirements; Through the above-mentioned detailed design, precise process control and strict testing, the present invention achieves the deep integration and optimization of aging-friendly, shock-absorbing and sound-absorbing functions, effectively circumvents the patent limitations of existing single-function floors, and provides high-performance, long-life, environmentally friendly and safe high-quality floor decoration solutions for elderly living environments, which has significant social value and market application prospects.

[0014] Please see the attached test report for details. Figure 3-5 . Example

[0015] See also Figure 1-2 The present invention provides a technical solution: an aging-friendly, shock-absorbing, and sound-absorbing wood composite floor, which is strictly laminated in a four-layer structure from top to bottom, with each layer having a clear division of labor and synergistic effects, forming an organic whole with complementary functions: First Layer: Wood Grain Finish Layer 1: 1.5mm thick LVT (vinyl laminate flooring) is used. Testing its water resistance reveals a thickness expansion rate of ≤0.5% after immersion for 24 hours. LVT offers enhanced wear resistance and water resistance, making it easy to clean and maintain, making it suitable for special areas such as bathrooms and kitchens. This layer also features an anti-slip treatment with a coefficient of friction of 0.6-0.8, effectively reducing the risk of slips for the elderly. Second layer: Shock-absorbing layer 2: 2.5mm thick IXPE (cross-linked polyethylene foam material) is purchased. Testing shows a compression rebound rate of ≥92%, environmental protection indicators, and heavy metal content that meets the GB6675.4-2014 standard. IXPE is made through chemical cross-linking and physical foaming processes, with a unique closed-cell structure that makes it highly elastic and aging-resistant, with a service life of over 15 years and excellent cushioning performance. Third layer: Wood core layer 3: Customized 10mm thick solid wood multilayer board (7-layer structure), which is made of an odd number of layers of veneer crisscrossed and hot-pressed. It has a stable structure, static bending strength ≥38MPa, and elastic modulus ≥4000MPa, overcoming the defects of traditional single-layer wood boards that are prone to warping and deformation. The back is provided with sound-absorbing grooves according to precise parameters. The grooves are 4.5mm deep, 3.0mm wide, and 15mm apart, arranged in a regular matrix. Based on the Holm-Hertz resonance cavity principle: when external sound waves are transmitted into the grooves, the air column in the cavity vibrates, and friction with the cavity wall consumes sound energy, achieving efficient absorption of noise of specific frequencies; The fourth layer: Sound-absorbing layer 4: 2.0mm thick polyurethane foam material is selected, with a porosity of ≥85% and a sound absorption coefficient of ≥0.7 at a frequency of 1000Hz; its internal porosity reaches 80%-90%, and the pore size distribution is uniform (10-50μm). After the sound waves enter the material, they are reflected and refracted multiple times in the pores, and the friction with the pore walls is converted into heat energy and dissipated. It has a significant absorption effect on medium and high frequency noise (800-5000Hz) (reduced by 20-30 decibels), and forms a dual sound-absorbing system with full coverage of "low frequency-medium and high frequency" with the sound-absorbing grooves of the wooden core layer.

[0016] Furthermore, the edges of the aging-friendly shock-absorbing and sound-absorbing wood composite floor are connected by locking slots.

[0017] The preparation method of the aging-friendly shock-absorbing and sound-absorbing wood composite floor comprises the following steps: 1. Gluing: Evenly apply water-based polyurethane adhesive on the back of the solid wood veneer using a roller coater, and control the glue application amount to 130g / ㎡; 2. Hot pressing: put the glued wood grain finishing layer 1 and IXPE cushioning layer 2 into a hot press at a temperature of 130°C and a pressure of 10 MPa for 8 minutes to form a composite unit of wood grain finishing layer 1 and cushioning layer 2; 3. Apply glue on the other side of IXPE, with a glue amount of 140g / ㎡, and hot press it with the wooden core layer 3, using the same hot pressing conditions as above; Fourth, apply glue on the back of the wooden core layer 3 at a rate of 120g / m2, and hot press it with the sound-absorbing layer 4 under the same hot pressing conditions as above to form a complete floor.

[0018] (3) Finished product inspection and acceptance Shock absorption performance: Impact absorption test is carried out in accordance with GB / T15102-2017 "Impregnated Paper Laminated Wood Flooring", and the impact absorption value is required to be ≥55%; Sound absorption performance: tested using the reverberation chamber method (GB / T20247-2006), the average sound absorption coefficient in the frequency range of 100-5000Hz is ≥0.5; Environmental indicators: Formaldehyde emission is tested according to GB18580-2017 (≤0.05mg / m³) to ensure that no harmful substances exceed the standard; Appearance and structure: Check whether the floor surface is flat and crack-free, whether the interlayer bonding is firm (peel strength test ≥1.5N / mm), and whether the size of the sound-absorbing groove meets the design requirements; Through the above-mentioned detailed design, precise process control and strict testing, the present invention achieves the deep integration and optimization of aging-friendly, shock-absorbing and sound-absorbing functions, effectively circumvents the patent limitations of existing single-function floors, and provides high-performance, long-life, environmentally friendly and safe high-quality floor decoration solutions for elderly living environments, which has significant social value and market application prospects.

[0019] Compared with the prior art, the present invention has the following beneficial effects: (1) Innovation of dual sound absorption system Combining the sound-absorbing grooves of the wood core (utilizing the Holm-Hertz resonance effect) with the sound-absorbing principle of the porous material in the sound-absorbing layer, this floor has been tested to reduce noise by 35-45 decibels in the frequency range of 100-5000Hz, more than double the effect of traditional single-structure flooring (which only reduces 15-20 decibels). (2) Deep integration of aging-friendly functions The IXPE shock-absorbing layer, combined with the anti-slip treatment of the wood-grain finish, provides comprehensive safety protection. In simulation tests, the floor's impact absorption reached 55%-60% when a 60kg object was dropped from a height of 30cm (far exceeding the national standard requirement of ≥45%), effectively protecting the mobility of the elderly. Furthermore, the material is environmentally friendly and non-toxic, meeting the needs of the elderly for a healthy living environment. (3) Structural performance optimization The solid wood multi-layer core layer gives the floor excellent structural stability. After a 24-hour boiling water immersion test, the water absorption thickness expansion rate is ≤8%, ensuring that it is not easily deformed in different temperature and humidity environments (temperature -10℃-40℃, humidity 40%-80%). The service life is extended to more than 20 years, reducing replacement costs. (4) Balance between environmental protection and economic efficiency Environmentally friendly materials and processes are selected, and the adhesives, IXPE and foam materials all comply with relevant national environmental protection standards; the production process is mature and can be produced on a large scale. Compared with similar imported aging-friendly floors, the cost is reduced by 30%-40%, and it has good market promotion potential.

[0020] While embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions, and variations may be made to these embodiments without departing from the principles and spirit of the invention, and that the scope of the invention is defined by the appended claims and their equivalents.

Claims

1. An aging-friendly, shock-absorbing, and sound-absorbing wood composite floor, characterized by: From top to bottom, the four-layer structure is strictly adhered to in an orderly manner. Each layer has a clear division of labor and works synergistically to form an organic whole with complementary functions: First layer: Wood grain finish layer—made from high-quality solid wood veneer with a thickness of 0.6-4.0mm or LVT with a thickness of 1.0-4.0mm. Solid wood veneer retains the natural wood grain, creating a warm and natural living atmosphere and providing a skin-friendly feel, which meets the elderly's preference for natural materials. LVT is more wear-resistant and waterproof, making it easy to clean and maintain, making it suitable for special areas such as bathrooms and kitchens. This layer has an anti-slip surface treatment with a friction coefficient of 0.6-0.8, effectively reducing the risk of slips for the elderly. Second layer: Shock-absorbing layer - Made of IXPE with a thickness of 1.0-4.0 mm. IXPE is made through chemical cross-linking and physical foaming processes, and has a unique closed-cell structure, making it highly elastic and resistant to aging, with a service life of over 15 years and excellent cushioning performance. The third layer: wooden core layer - uses solid wood multi-layer boards with a thickness of 8-15mm. It is made of an odd number of layers of veneer that are crisscrossed and hot-pressed. It has a stable structure, a static bending strength of ≥35MPa, and an elastic modulus of ≥4000MPa. It overcomes the defects of traditional single-layer wood boards that are prone to warping and deformation. The back is provided with sound-absorbing grooves according to precise parameters. The grooves are 4-10mm deep, 2.0-4.5mm wide, and 15-50mm apart. They are arranged in a regular matrix. Based on the Holm-Hertz resonance cavity principle: when external sound waves are transmitted into the grooves, the air column in the cavity vibrates, and friction with the cavity wall consumes sound energy, achieving efficient absorption of noise of specific frequencies; The fourth layer: sound-absorbing layer - uses foamed sound-absorbing material with a thickness of 1.5-5.0mm. Its internal porosity reaches 80%-90%, and the pore size is evenly distributed at 10-50μm. After the sound waves enter the material, they are reflected and refracted multiple times in the pores, and the friction with the pore walls is converted into heat energy and dissipated. It has a significant effect on absorbing medium and high frequency noise of 800-5000Hz, and forms a dual sound-absorbing system with full coverage of "low frequency-medium and high frequency" with the sound-absorbing grooves of the wooden core layer.

2. The aging-friendly, shock-absorbing, and sound-absorbing wood composite floor according to claim 1, characterized in that: The edges are connected with locking card slots.

3. The method for preparing the aging-friendly, shock-absorbing, and sound-absorbing wood composite floor according to claim 1 or 2, characterized in that: The following steps are involved: Water-based polyurethane environmentally friendly adhesive is used between each layer, and is evenly applied by high-precision gluing equipment with a glue coating amount of 120-150g / ㎡; During hot pressing, the temperature should be controlled at 120-140℃, the pressure should be 8-12MPa, and the time should be 8-10 minutes to ensure that the interlayers are firmly bonded and the peel strength is ≥1.5 N / mm. At the same time, avoid degradation of material properties due to high temperature.

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