Composite foamed SPC floor and production process thereof

Abstract

This invention discloses a composite foamed SPC flooring and its manufacturing process, relating to the technical field of scratch-resistant layered products. A composite foamed SPC flooring comprises, from top to bottom: a UV-absorbing wear-resistant layer, a foamed polyvinyl chloride (PVC) material layer, and a stabilizing layer. The UV-absorbing wear-resistant layer is composed of a UV-absorbing wear-resistant material comprising the following components by weight: polyurethane acrylic resin: 50-70 parts, alumina: 15-30 parts, nano-silica: 5-10 parts, polyvinyl chloride: 20-40 parts, defoamer: 0.5-1.5 parts, leveling agent: 0.3-1.0 parts, and UV absorber: 1-2.5 parts. This invention, by employing a specific UV absorber, slows down the aging process of the material, maintaining the appearance and performance of the flooring. Through a rationally designed three-layer structure, optimizing the composition and manufacturing process of each layer, the interlayer bonding is enhanced, ensuring the long-term performance and aesthetics of the flooring.

Description

Technical Field

[0001] This invention relates to the field of scratch-resistant layered products, specifically to a composite foamed SPC flooring and its manufacturing process. Background Technology

[0002] With the development of the building decoration industry, the demand for flooring materials is constantly increasing, and the requirements for flooring performance are also becoming more stringent. Traditional flooring materials such as solid wood flooring and ceramic tiles, while possessing certain aesthetic appeal and durability, have many shortcomings in terms of scratch resistance, wear resistance, environmental friendliness, and ease of installation. In recent years, SPC boards, as a new type of environmentally friendly flooring material, have gradually gained market favor due to their excellent wear resistance, water resistance, and ease of installation.

[0003] Existing SPC flooring still needs improvement in certain performance aspects. The wear layer of ordinary SPC flooring may not meet the needs of high-intensity use environments, especially in public places or high-traffic areas, where the floor surface is prone to scratches and wear, affecting its service life and aesthetics. In addition, the foam layer of existing SPC flooring technology also has certain limitations in terms of stability and load-bearing capacity, which may lead to deformation or collapse of the flooring after long-term use.

[0004] To overcome the shortcomings of existing technologies, this invention proposes a composite foamed SPC flooring and its manufacturing process. This flooring significantly improves scratch resistance and service life by optimizing the composition and structure of each layer and introducing a high-performance UV-absorbing wear-resistant layer. Simultaneously, improvements to the foamed polyvinyl chloride (PVC) material layer and stabilizing layer further enhance the overall stability and load-bearing capacity of the flooring. This composite foamed SPC flooring not only outperforms traditional flooring materials but also excels in environmental protection and sustainability, meeting the demands of the modern building decoration industry for green building materials. Summary of the Invention

[0005] The purpose of this invention is to address the problems existing in the prior art by providing a scratch-resistant stone plastic flooring that is highly wear-resistant, waterproof, has excellent UV aging resistance, and strong interlayer bonding.

[0006] To achieve the above objectives, the technical solution adopted by the present invention is: a composite foamed SPC flooring, comprising, from top to bottom: an ultraviolet-absorbing wear-resistant layer, a foamed polyvinyl chloride material layer, and a stabilizing layer;

[0007] The thickness of the ultraviolet-absorbing wear-resistant layer is 0.1-0.3 mm, the thickness of the foamed polyvinyl chloride material layer is 2.0-5.0 mm, and the thickness of the stabilizing layer is 1.5-3.0 mm.

[0008] The ultraviolet-absorbing wear-resistant layer is composed of an ultraviolet-absorbing wear-resistant material, which comprises the following components by weight: polyurethane acrylic resin: 50-70 parts, alumina: 15-30 parts, nano silica: 5-10 parts, polyvinyl chloride: 20-40 parts, defoamer: 0.5-1.5 parts, leveling agent: 0.3-1.0 parts, and ultraviolet absorber: 1-2.5 parts.

[0009] The ultraviolet absorber is a compound represented by Formula 1:

[0010]

[0011] R1 is selected from: methyl, phenyl, naphthyl, tert-butylphenyl.

[0012] Furthermore, the polyurethane acrylate resin is at least one of aliphatic polyurethane trimethacrylate resin, aliphatic polyurethane tetramethacrylate resin, and aliphatic polyurethane pentamethacrylate resin.

[0013] Furthermore, the alumina particle size is 10-50 nm.

[0014] Furthermore, the particle size of the nano-silica is 10-50 nm.

[0015] Furthermore, the defoamer is at least one of BYK022 defoamer, BYK037 defoamer, and BYK051 defoamer.

[0016] Furthermore, the leveling agent is at least one of BYK-346 or BYK-358N.

[0017] Furthermore, the preparation method of the ultraviolet-absorbing wear-resistant material is as follows: the polyurethane acrylic resin, alumina, nano silica, polyvinyl chloride, defoamer, leveling agent, and ultraviolet absorber are added to a mixer and mixed at 80-120°C for 10-15 minutes to obtain a mixture; the mixture is added to a twin-screw extruder and melt-extruded at 150-200°C, granulated, and cooled to room temperature to obtain the ultraviolet-absorbing wear-resistant material.

[0018] Furthermore, the ultraviolet absorber is any one of the compounds shown in the following structures:

[0019]

[0020] A manufacturing process for composite foamed SPC flooring includes the following steps:

[0021] S1. Preparation of UV-absorbing wear-resistant layer: UV-absorbing wear-resistant material is prepared according to the above method and calendered into a film with a thickness of 0.1-0.3 mm;

[0022] S2. Preparation of foamed polyvinyl chloride material layer: The polyvinyl chloride resin and foaming agent are added to a mixer and mixed at 100-150℃ for 5-10 minutes to obtain a mixture; the mixture is placed in a mold and foamed at 120-160℃ to form a thickness of 2.0-5.0 mm.

[0023] S3. Preparation of the stabilizing layer: The cork raw material is hot-pressed at 120-150℃ into a sheet with a thickness of 1.5-3.0 mm;

[0024] S4. Composite Step: The ultraviolet-absorbing wear-resistant layer, the foamed polyvinyl chloride material layer and the stabilizing layer are sequentially stacked and hot-pressed in a hot press at 130-170℃ and 5-15MPa for 10-20 minutes to obtain a composite foamed SPC floor.

[0025] Furthermore, the foaming agent is azodicarbonamide.

[0026] The UV absorber described in this invention absorbs high-energy ultraviolet radiation (wavelength 280-400nm) through specific functional groups in its molecular structure, converting UV energy into a low-energy form. This prevents UV light from directly attacking the material's molecular chains, reducing UV damage to the resin matrix and thus extending the floor's lifespan. Under high-temperature processing or light exposure conditions, it can capture free radicals generated by the degradation of polyvinyl chloride (PVC), inhibiting chain oxidation reactions and delaying material aging.

[0027] The scratch-resistant stone-plastic flooring of this invention features a three-layer structure (UV-absorbing wear-resistant layer, foamed polyvinyl chloride vinyl layer, and stabilizing layer) and the synergistic effect of specific components, solving the technical problems of poor wear resistance, insufficient UV resistance, and weak interlayer bonding in ordinary SPC flooring. Polyurethane acrylic resin, as the matrix resin, provides high hardness and flexibility. Its molecular chains form a cross-linked network, enhancing wear resistance. In synergy with other fillers, it forms a dense structure, reducing surface scratches. Alumina and nano-silica, as inorganic nanofillers, improve the material's hardness and wear resistance through nano-effects, synergistically filling the pores of the resin matrix, reducing stress concentration, thereby improving impact resistance and surface smoothness. Meanwhile, the uniform dispersion of nanoparticles forms a barrier layer, blocking external mechanical damage. The good compatibility between PVC and polyurethane acrylic resin provides rigidity and cost-effectiveness, serving as an auxiliary matrix to enhance interlayer bonding and prevent delamination during hot pressing. Defoamers and leveling agents eliminate air bubbles during processing, improve material flowability, ensure uniform mixing of components, reduce surface defects, enhance the smoothness and consistency of the wear-resistant layer, and prevent premature wear caused by localized weaknesses. UV absorbers are key components for UV aging resistance; they absorb high-energy ultraviolet rays through specific functional groups in their molecular structure, converting UV radiation into heat energy for dissipation, preventing UV light from attacking the resin molecular chains, and reducing photodegradation. The twin-screw extrusion and continuous lamination processes ensure uniform component dispersion and tight interlayer bonding, ultimately achieving high wear resistance, long-lasting UV aging resistance, and strong overall bonding, meeting the stringent durability requirements of high-traffic areas for flooring.

[0028] By adopting the above technical solution

[0029] Compared with the prior art, the beneficial effects of the present invention are:

[0030] 1. Significantly Enhanced Abrasion Resistance and Impact Resistance: By optimizing the material formulation of the UV-absorbing abrasion layer and introducing components such as polyurethane acrylic resin, alumina, and nano-silica, a composite structure with high hardness and high toughness is formed. This structure not only enhances the abrasion resistance of the floor surface but also improves the impact resistance of the floor through the synergistic effect of nanofillers, enabling it to effectively resist scratches and impact damage under high-intensity use environments and extend its service life.

[0031] 2. Enhanced weather resistance and UV aging resistance: Utilizing specific UV absorbers, it effectively absorbs high-energy ultraviolet radiation and converts it into a low-energy form, thereby reducing the damage of ultraviolet rays to the resin matrix. This UV aging resistance significantly improves the stability of the flooring under long-term light exposure, slows down the aging process of the material, maintains the appearance and performance of the flooring, and makes it more suitable for outdoor or high-light locations.

[0032] 3. Improved interlayer bonding and overall stability: By rationally designing the three-layer structure (UV-absorbing wear-resistant layer, foamed PVC layer, and stabilizing layer) and optimizing the composition and manufacturing process of each layer, the interlayer bonding strength is enhanced. Simultaneously, improvements to the foamed PVC layer and stabilizing layer further improve the overall stability and load-bearing capacity of the flooring, making it less prone to deformation or collapse during long-term use, thus ensuring the flooring's long-term performance and aesthetics. Attached Figure Description

[0033] Figure 1 This is a schematic diagram of a composite foamed SPC flooring structure according to the present invention;

[0034] 1 is the UV-absorbing wear-resistant layer, 2 is the foamed polyvinyl chloride material layer, and 3 is the stabilizing layer.

[0035] Figure 2 The ultraviolet absorber 1 described in this invention 1 HNMR image Detailed Implementation

[0036] The technical solution of the present invention will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are merely some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0037] Synthesis example 1

[0038] Synthesis of UV absorber 1:

[0039]

[0040] A1: Under a nitrogen atmosphere, 20 g of starting material 1, 13.59 g of starting material 2, 19.18 g of anhydrous potassium carbonate, 1.60 g of tetra(triphenylphosphine)palladium, and 230 g of toluene were added to the reaction system. The mixture was heated to 95°C and refluxed for 10 hours. The heating was then turned off, and the mixture was cooled to room temperature. The mixture was allowed to stand and separated. The aqueous phase was extracted twice with ethyl acetate. The organic phases were combined and dried over anhydrous magnesium sulfate. The mixture was filtered, evaporated to dryness, and subjected to silica gel column chromatography using a mixture of petroleum ether and ethyl acetate as eluent. The solution was evaporated to dryness to obtain 21.38 g of UV absorber 1. MS (m / z): [M+H] + =575.

[0041] Structural identification of UV absorber 1: 1HNMR Chloroform-d: 8.23(dd,1H),8.06(dd,1H),7.92(dd,1H),7.79(s,1H),7.65-7.54(m,2H),7.51(dt,1H),7.29-7.0 6(m,5H),7.06-6.97(m,1H),6.90(dd,6H),3.60(d,2H),2.87-2.64(m,2H),1.61(s,6H),1.42(d,6H),1.33(s,3H).

[0042] Synthesis Example 2-Synthesis Example 4

[0043] In Synthesis Examples 2-4, UV absorber 2-UV absorber 4 were synthesized sequentially, following the same synthesis method as in Synthesis Example 1, except that raw material 2 was replaced; the rest remained the same as in Synthesis Example 1. Specific structures of raw material 2, UV absorber 2-UV absorber 4, and MS (m / z): [M+H] are detailed below. + Data is shown in Table 1

[0044] Table 1. Structures of raw material 2, UV absorber 2-UV absorber 4, and MS (m / z): [M+H] involved in Synthesis Examples 2-4 + data.

[0045]

[0046] Example 1

[0047] Production of a composite foamed SPC flooring:

[0048] A composite foamed SPC flooring consists of a three-layer structure stacked from top to bottom, including a 0.2mm thick UV-absorbing wear-resistant layer, a 3mm thick foamed polyvinyl chloride material layer, and a 2mm thick stabilizing layer.

[0049] The UV-absorbing wear-resistant layer is composed of UV-absorbing wear-resistant material; the foamed polyvinyl chloride material layer is composed of polyvinyl chloride resin and foaming agent (purchased from: Xingyang No.10 Chemical Co., Ltd.); the stabilizing layer is composed of cork (purchased from: Xi'an Sandi Cork Co., Ltd., No. FD).

[0050] The ultraviolet-absorbing wear-resistant material comprises the following components in parts by weight:

[0051] Polyurethane acrylic resin: 60 parts, which is an aliphatic polyurethane trimethacrylic resin;

[0052] Alumina: 20 parts, particle size 50 nm;

[0053] Nano-silica: 8 parts, particle size 50nm

[0054] Polyvinyl chloride: 30 parts;

[0055] Defoamer: 1 part, BYK022 defoamer (purchased from Guangzhou Qianguang Trading Co., Ltd.);

[0056] Leveling agent: 0.5 parts, BYK-346 (purchased from Guangdong Wengjiang Chemical Reagent Co., Ltd., product number PB21308)

[0057] UV absorber: 2 parts (UV absorber 1 synthesized in Synthesis Example 1).

[0058] Production method:

[0059] S1. Preparation of UV-absorbing wear-resistant layer: 60 parts of polyurethane acrylic resin, 20 parts of alumina, 8 parts of nano silica, 30 parts of polyvinyl chloride, 1 part of defoamer, 0.5 parts of leveling agent, and 2 parts of UV absorber are added to a mixer and mixed at 100°C for 15 minutes to obtain a mixture; the mixture is added to a twin-screw extruder, melt-extruded and granulated at 160°C, and cooled to room temperature to obtain the UV-absorbing wear-resistant material, which is then calendered into a film with a thickness of 0.2 mm;

[0060] S2. Preparation of foamed polyvinyl chloride material layer: Polyvinyl chloride resin and azodicarbonamide are added to a mixer and mixed at 120°C for 10 minutes to obtain a mixture; the mixture is placed in a mold and foamed at 150°C to form a thickness of 3 mm.

[0061] S3. Preparation of stabilizing layer: Cork raw material is hot-pressed at 135℃ into a sheet with a thickness of 2mm;

[0062] S4. Composite Step: The UV-absorbing wear-resistant layer, the foamed polyvinyl chloride material layer and the stabilizing layer are sequentially stacked and hot-pressed in a hot press at 150°C and 10MPa for 20 minutes to obtain a composite foamed SPC floor.

[0063] Examples 2-4

[0064] The production of a composite foamed SPC flooring follows the production process of Example 1, except that the ultraviolet absorber is replaced sequentially with ultraviolet absorber 2-ultraviolet absorber 4 synthesized in Synthesis Examples 2-4, while the rest remains the same as in Example 1.

[0065] Comparative Example 1

[0066] The production of a composite foamed SPC flooring follows the same process as in Example 1, except that the ultraviolet absorber is replaced with comparative compound 1, while the rest remains the same as in Example 1.

[0067] Comparative compound 1: UV absorber UV-326.

[0068] Comparative Example 2

[0069] The production of a composite foamed SPC flooring follows the same process as in Example 1, except that the ultraviolet absorber is replaced with comparative compound 2, while the rest remains the same as in Example 1.

[0070] Comparative compound 2:

[0071] Comparative Example 3

[0072] The production of a composite foamed SPC flooring follows the same process as in Example 1, except that no ultraviolet absorber is added, and the rest remains the same as in Example 1.

[0073] Comparative Example 4

[0074] The production of a composite foamed SPC flooring follows the same process as in Example 1, except that the mass fraction of polyurethane acrylic resin is changed to 40 parts, while the rest remains the same as in Example 1.

[0075] Comparative Example 5

[0076] The production of a composite foamed SPC flooring follows the same process as in Example 1, except that the mass fraction of polyvinyl chloride is replaced with 50 parts, while the rest remains the same as in Example 1.

[0077] Performance testing:

[0078] 1. Mechanical property testing: Pencil hardness was tested according to GB / T 6739-2022 standard; impact performance was tested according to GB / T 1732-2020 standard, and the data are shown in Table 2.

[0079] 2. Weathering resistance test: The test was conducted according to the conditions specified in standard GB / T 1865-2009. During the test, the parameters such as the irradiance of the xenon arc lamp, the blackboard temperature, the relative humidity, and the water spray cycle of each sample were kept consistent to simulate the changes in light, temperature, and humidity in the natural environment. The test was conducted continuously for 2000 hours. The test specimens were then removed and the color change (ΔE / %) before and after aging was measured using a colorimeter. The experimental data are shown in Table 2. Then, the tested specimens were subjected to pencil hardness testing according to standard GB / T 6739-2022 and impact performance testing according to standard GB / T 1732-2020. The data are shown in Table 2.

[0080] Table 2. Performance test data of a composite foamed SPC floor prepared in the examples and comparative examples.

[0081]

[0082] Examples 1-4 demonstrated excellent performance across all test dimensions, including high pencil hardness, good impact resistance (no signs of cracking), minimal color change before and after aging, and excellent performance retention after aging. This indicates that the combination of specific UV absorbers significantly improves the flooring's abrasion resistance, stability, and weather resistance. In contrast, Comparative Examples 1-5 showed a downward trend in several aspects: Comparative Examples 1-2, using alternative UV absorbers, exhibited reduced hardness, impact resistance, and color stability, with a significant decrease in performance retention after aging; Comparative Example 3, lacking a UV absorber, resulted in the worst overall performance; Comparative Example 4, by reducing the polyurethane acrylic resin content, showed weakened hardness and impact resistance, and worsened color stability; Comparative Example 5, while showing slightly better overall performance than the other comparative examples due to the increased polyvinyl chloride proportion, still fell short of the overall performance level of the examples. These trends illustrate the synergistic effect of the UV absorbers and formulation components of this invention, effectively ensuring the flooring's high durability and anti-aging capabilities during long-term use.

[0083] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A composite foamed SPC floor, characterized in that, From top to bottom, it includes: UV-absorbing wear-resistant layer (1), foamed polyvinyl chloride material layer (2), and stabilizing layer (3); The thickness of the ultraviolet-absorbing wear-resistant layer (1) is 0.1-0.3 mm, the thickness of the foamed polyvinyl chloride vinyl material layer (2) is 2.0-5.0 mm, and the thickness of the stabilizing layer (3) is 1.5-3.0 mm; The ultraviolet-absorbing wear-resistant layer (1) is composed of an ultraviolet-absorbing wear-resistant material, which contains the following components by weight: polyurethane acrylic resin: 50-70 parts, alumina: 15-30 parts, nano silica: 5-10 parts, polyvinyl chloride: 20-40 parts, defoamer: 0.5-1.5 parts, leveling agent: 0.3-1.0 parts, and ultraviolet absorber: 1-2.5 parts; The ultraviolet absorber is a compound represented by Formula 1: Formula 1; R1 is selected from: methyl, phenyl, naphthyl, tert-butylphenyl.

2. The composite foamed SPC floor according to claim 1, characterized in that, The polyurethane acrylate resin is at least one of aliphatic polyurethane trimethacrylate resin, aliphatic polyurethane tetramethacrylate resin, and aliphatic polyurethane pentamethacrylate resin.

3. The composite foamed SPC floor according to claim 1, characterized in that, The alumina particle size is 10-50 nm.

4. The composite foamed SPC flooring according to claim 1, characterized in that, The particle size of the nano-silica is 10-50 nm.

5. The composite foamed SPC flooring according to claim 1, characterized in that, The defoamer is at least one of BYK022 defoamer, BYK037 defoamer, and BYK051 defoamer.

6. The composite foamed SPC floor according to claim 1, characterized in that, The leveling agent is at least one of BYK-346 or BYK-358N.

7. The composite foamed SPC floor according to claim 1, characterized in that, The method for preparing the ultraviolet-absorbing wear-resistant material is as follows: the polyurethane acrylic resin, alumina, nano silica, polyvinyl chloride, defoamer, leveling agent, and ultraviolet absorber are added to a mixer and mixed at 80-120℃ for 10-15 minutes to obtain a mixture; the mixture is added to a twin-screw extruder and melt-extruded at 150-200℃, granulated, and cooled to room temperature to obtain the ultraviolet-absorbing wear-resistant material.

8. A production process of the composite foamed SPC floor according to any one of claims 1-7, characterized in that, Includes the following steps: S1. Preparation of UV-absorbing wear-resistant layer (1): UV-absorbing wear-resistant material is prepared according to the method described in claim 7 and calendered into a film with a thickness of 0.1-0.3 mm; S2. Preparation of foamed polyvinyl chloride material layer (2): Add polyvinyl chloride resin and foaming agent to a mixer and mix at 100-150℃ for 5-10 minutes to obtain a mixture; place the mixture in a mold and foam it at 120-160℃, controlling the thickness to be 2.0-5.0mm; S3. Preparation of stabilizing layer (3): The cork raw material is hot-pressed at 120-150℃ into a thin sheet with a thickness of 1.5-3.0 mm; S4. Composite Step: The UV-absorbing wear-resistant layer (1), the foamed polyvinyl chloride material layer (2) and the stabilizing layer (3) are sequentially stacked and hot-pressed in a hot press at 130-170℃ and 5-15MPa for 10-20 minutes to obtain a composite foamed SPC floor.

9. The production process of a composite foamed SPC floor according to claim 8, characterized in that, The foaming agent is azodicarbonamide.

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