Ultrathin marble-ocean plate composite floor and preparation method thereof

Abstract

The invention relates to the technical field of building decoration, and discloses an ultra-thin marble-ocean plate composite floor and a preparation method thereof.The composite floor is sequentially composed of an ultra-thin marble layer, an elastic bonding layer and an ocean plate base layer from top to bottom, and raw materials of each layer comprise, by mass, 35%-45% of a natural marble plate, 20%-30% of an ocean plate base layer and 20%-30% of an ocean plate base layer; the nano silicon dioxide wear-resistant coating accounts for 1-3% of the total mass of the composite The epoxy resin E-44 accounts for 4-6% of the total mass of the composite floor; the hollow glass beads account for 15-25% of the mass of the bonding layer; the phenolic resin glue accounts for 8-12% of the mass of the ocean plate base layer The birch veneer accounts for 45%-55% of the total mass of the composite floor, through grid etching toughening treatment of the ultra-thin marble layer, buffering design of the elastic bonding layer containing the micro air bags and a lock catch splicing structure of the high-stability ocean plate base layer, the ultra-thinness, light weight, high impact resistance, seamless splicing, rapid installation and excellent thermal stability of the floor are successfully achieved, and meanwhile, the composite floor has the advantages of being simple in structure, convenient to use and high in practicability. The preparation process is green and environment-friendly.

Description

Technical Field

[0001] This invention relates to the field of building decoration technology, specifically to an ultra-thin marble-ocean slab composite floor and its preparation method. Background Technology

[0002] In the field of building decoration materials, existing technical solutions generally suffer from the following significant drawbacks: First, while stone composite panels (such as marble and honeycomb aluminum-based composite structures) possess a certain degree of decorative appeal, they have obvious shortcomings—poor sound insulation, a cold feel underfoot, and due to the large difference in thermal expansion coefficients between metal and stone, they are prone to delamination caused by internal stress due to temperature changes. Furthermore, their edge structure cannot be directly spliced ​​with wooden flooring, requiring transition strips to compensate for height differences, affecting the overall aesthetics. Second, pure marine-grade flooring is limited by the inherent characteristics of wood, resulting in low surface hardness and weak impact resistance, making it difficult to meet the needs of high-traffic areas. Third, traditional marble paving processes rely on a cement mortar leveling layer with an overall thickness ≥30mm, resulting in excessive weight, increasing building load, and causing long construction cycles and complex procedures. These technical bottlenecks prevent existing solutions from simultaneously meeting the four core requirements of ultra-thinness, high impact resistance, seamless splicing, and rapid installation, severely restricting the application and promotion of stone composite flooring in high-end residential and commercial spaces. Summary of the Invention

[0003] (a) Technical problems to be solved

[0004] To address the shortcomings of existing technologies, this invention provides an ultra-thin marble-ocean slab composite floor and its preparation method. It has the advantages of being ultra-thin and lightweight, highly impact-resistant, seamlessly spliced, quick to install, and environmentally friendly and healthy. It solves the problems of traditional stone composite panels being prone to delamination and breakage, incompatibility with wood flooring, and low construction efficiency, as well as the problems of insufficient surface hardness and poor impact resistance of pure ocean slab flooring.

[0005] (II) Technical Solution

[0006] To achieve the above objectives, the present invention provides the following technical solution: an ultra-thin marble-ocean slab composite flooring, wherein the composite flooring is composed of an ultra-thin marble layer, an elastic adhesive layer, and an ocean slab base layer from top to bottom. The raw materials and their mass percentages for each layer are as follows: natural marble slabs account for 35% to 45% of the total mass of the composite flooring; nano-silica wear-resistant coating accounts for 1% to 3% of the total mass of the composite flooring; epoxy resin E-44 accounts for 4% to 6% of the total mass of the composite flooring; hollow glass microspheres account for 15% to 25% of the mass of the adhesive layer; phenolic resin adhesive accounts for 8% to 12% of the mass of the ocean slab base layer; and birch veneer accounts for 45% to 55% of the total mass of the composite flooring.

[0007] Preferably, the nano-silica wear-resistant coating is a silica sol system with a solid content ≥30%; the epoxy resin E-44 has an epoxy value of 0.44–0.51 mol / 100g; and the hollow glass microspheres have a particle size of 10–50 μm and a density of 0.15–0.25 g / cm³. 3 The phenolic resin adhesive has a solid content of 45%–50% and free formaldehyde ≤0.1%; the birch veneer has a thickness of 1.2–1.8 mm and a moisture content of 6%–8%.

[0008] A method for preparing ultra-thin marble-ocean slab composite flooring, comprising the following steps, based on the raw materials and their mass percentages described above:

[0009] Step 1: Prepare natural marble slabs, nano-silica wear-resistant coating, epoxy resin E-44, hollow glass microspheres, phenolic resin glue, and birch veneer according to the formula weight percentages.

[0010] Step 2, Preparation of ultra-thin marble layer: The natural marble slab is cut into thin slices of 750-800mm × 750-800mm × 0.5-1mm using a five-axis water jet cutter to obtain an ultra-thin marble layer;

[0011] Step 3: Preparation of marine board base layer: Dry birch veneer to a moisture content of 6% to 8%, impregnate with phenolic resin, lay in a 0° / 90° cross pattern and then hot press to obtain the marine board base layer;

[0012] Step 4: Preparation of elastic adhesive layer: Epoxy resin E-44, hollow glass microspheres and additives are vacuum stirred and degassed to obtain elastic adhesive;

[0013] Step 5, Cold Pressing: Apply elastic adhesive evenly to the back of the ultra-thin marble layer, and then cold press it with the marine board base layer under set conditions to obtain the preliminary composite flooring;

[0014] Step 6, Surface abrasion resistance treatment: Spray nano-silica abrasion-resistant coating onto the marble surface of the composite flooring, and dry and cure at 80-100℃ for 2-3 hours;

[0015] Step 7: Post-processing: The composite flooring is polished and beveled to obtain ultra-thin marble-ocean slab composite flooring. After passing quality inspection, it is packaged.

[0016] Preferably, the ultrathin marble layer preparation process in step two is as follows:

[0017] S1.1 Mineral processing: Select Class A natural marble slabs with radioactivity ≤0.3Bq / g;

[0018] S1.2 Thinning: Five-axis water jet cutting is used, with the jet pressure controlled at 300-400mPa and the speed controlled at 180-200mm / min;

[0019] S1.3 Etching: Under etching conditions of laser power of 200-250W and scanning speed of 3-5m / s, a uniform mesh of 20-40 mesh and depth of 0.1-0.2mm is formed;

[0020] S1.4 Cutting: Finally, process into thin slices of 750~800mm×750~800mm×0.5~1mm to obtain an ultra-thin marble layer for later use.

[0021] Preferably, in step three, the marine board base layer is composed of 7-9 layers of birch veneer, which is impregnated with phenolic resin for 2-4 hours, and then hot-pressed in a 0° / 90° cross pattern to control the thickness of 8-12mm; its two sides are pre-milled with double barbed locking buckles with a locking groove depth of 2.0-2.2mm, which can be directly spliced ​​with solid wood flooring, and the height difference after splicing is ≤0.3mm, for later use.

[0022] Preferably, the hot pressing conditions in step three are: temperature 135-145℃, pressure 1.0-1.2mPa, time 15-20min, and pressure released after cooling to ≤40℃.

[0023] Preferably, in step four, the elastic adhesive layer is made by mixing epoxy resin E-44 and hollow glass microspheres at a mass ratio of 95-100:15-25, and adding 1% to 2% of silane coupling agent KH-560 and 0.5% to 1% of defoamer as a percentage of the total elastic adhesive layer mass. After curing, a buffer structure containing micro-airbags is formed with a shear strength ≥8MPa, which is then ready for use.

[0024] Preferably, the vacuum stirring conditions in step four are: vacuum degree -0.09 to -0.08 mPa, rotation speed 300-400 rpm, time 8-10 min, and viscosity of the adhesive controlled at 1500-2000 mPa·s.

[0025] Preferably, the cold pressing conditions in step five are: pressure 0.5-0.8 mPa, temperature 20-25℃, curing time 48-72 h; and peel strength after curing ≥2.5 N / mm.

[0026] Preferably, the post-processing procedure in step seven is as follows:

[0027] S2.1 Surface polishing: Polish step by step using 400-1000 grit diamond grinding discs until the gloss level is ≥90gU;

[0028] S2.2, Chamfering: Chamfer all four sides with a radius of 0.4-0.5mm to prevent chipping;

[0029] S2.3 Quality Inspection and Packaging: Each piece undergoes drop ball impact testing (1100-1200mm), static bending strength ≥28mPa, and formaldehyde emission ≤0.02mg / m³. 3 After passing the inspection, the products are covered with PE protective film and packed into honeycomb cardboard boxes.

[0030] Compared with the prior art, the present invention provides an ultra-thin marble-ocean slab composite floor and its preparation method, which has the following beneficial effects:

[0031] 1. This invention significantly improves the impact resistance and structural stability of composite flooring through the synergistic design of laser mesh etching of an ultra-thin marble layer and the micro-airbag buffer structure formed by hollow glass microspheres in the elastic adhesive layer. The mesh etching increases the contact area and mechanical interlocking effect between the marble and the adhesive layer, effectively improving the interlayer bonding force and stress dispersion ability. The introduction of hollow glass microspheres causes the adhesive layer to undergo elastic deformation when impacted, absorbing and dispersing energy and preventing stress concentration on the marble surface. The synergistic effect of the two increases the drop ball impact height and peel strength of the finished flooring, improving its impact resistance compared to traditional marble-aluminum composite flooring and completely solving the delamination and breakage problems caused by thermal expansion and contraction or external impact of this type of product.

[0032] 2. This invention utilizes a 0° / 90° cross-laying structure for 7-9 layers of birch veneer in the marine board base layer, combined with a pre-milled double-hook locking design on the sides, and an industrialized composite process combining hot and cold pressing. This achieves ultra-high dimensional stability, seamless splicing capability, and rapid construction characteristics for the composite flooring. The cross-laying structure significantly reduces internal stress caused by the anisotropy of the wood, resulting in low thermal deformation under a 20°C temperature difference. Simultaneously, the double-hook locking design allows for direct splicing with solid wood flooring with minimal height difference, eliminating the need for transition strips. Combined with the overall thin and lightweight characteristics of the flooring, no cement mortar leveling is required on-site, achieving an installation efficiency of up to 2 days / 100m². 2 Compared to traditional marble paving, it is several times more efficient, thus greatly expanding its application in high-end residential and commercial spaces where there are high requirements for floor flatness and aesthetic splicing.

[0033] 3. This invention reduces the thickness of natural marble to 0.5-1mm using a five-axis waterjet cutter and employs low-formaldehyde phenolic resin adhesive and environmentally friendly epoxy resin adhesive, thereby simultaneously achieving a significant reduction in raw material costs and an improvement in the green and environmentally friendly quality of the product. The ultra-thin design reduces the amount of marble used and lowers the surface density, thus significantly saving on raw material and transportation costs. Furthermore, the use of carefully selected environmentally friendly adhesives combined with birch veneer low moisture content control technology ensures that the formaldehyde emission of the finished product is ≤0.02mg / m³. 3It meets the ENF standard. This design not only conforms to the development trend of green building materials, but also avoids indoor environmental pollution, ultimately meeting consumers' high requirements for healthy homes, while significantly reducing the overall cost of production and application. Attached Figure Description

[0034] Figure 1 This is a flowchart illustrating the preparation process of the composite flooring of the present invention. Detailed Implementation

[0035] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only 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.

[0036] Please see Figure 1 An ultra-thin marble-ocean slab composite flooring is disclosed. The composite flooring consists of, from top to bottom, an ultra-thin marble layer, an elastic adhesive layer, and an ocean slab base layer. The raw materials and their weight percentages for each layer are as follows: natural marble slabs account for 35%–45% of the total weight of the composite flooring; nano-silica wear-resistant coating accounts for 1%–3% of the total weight of the composite flooring; epoxy resin E-44 accounts for 4%–6% of the total weight of the composite flooring; hollow glass microspheres account for 15%–25% of the adhesive layer; phenolic resin adhesive accounts for 8%–12% of the weight of the ocean slab base layer; and birch veneer accounts for 45%–55% of the total weight of the composite flooring.

[0037] Specifically, the raw materials and their functions are shown in Table 1 below:

[0038] Table 1

[0039]

[0040]

[0041] Specifically, the nano-silica wear-resistant coating is a silica sol system with a solid content ≥30%; the epoxy resin E-44 has an epoxy value of 0.44~0.51mol / 100g; the hollow glass microspheres have a particle size of 10-50um and a density of 0.15~0.25g / cm³. 3 The phenolic resin adhesive has a solid content of 45%–50% and free formaldehyde ≤0.1%; the birch veneer has a thickness of 1.2–1.8 mm and a moisture content of 6%–8%.

[0042] The advantages are: through the high solids content system of the above-mentioned nano-silica wear-resistant coating, the suitable epoxy value of epoxy resin E-44, the lightweight microsphere structure of hollow glass microspheres, the low formaldehyde release phenolic resin adhesive, and the birch veneer with strict control of thickness and moisture content, the prepared composite flooring has excellent surface wear resistance, good bonding strength, significant cushioning performance, environmental safety, and dimensional stability.

[0043] A method for preparing ultra-thin marble-ocean slab composite flooring, comprising the following steps, based on the raw materials and their mass percentages described above:

[0044] Step 1: Prepare natural marble slabs, nano-silica wear-resistant coating, epoxy resin E-44, hollow glass microspheres, phenolic resin glue, and birch veneer according to the formula weight percentages.

[0045] Step 2, Preparation of ultra-thin marble layer: The natural marble slab is cut into thin slices of 750-800mm × 750-800mm × 0.5-1mm using a five-axis water jet cutter to obtain an ultra-thin marble layer;

[0046] Step 3: Preparation of marine board base layer: Dry birch veneer to a moisture content of 6% to 8%, impregnate with phenolic resin, lay in a 0° / 90° cross pattern and then hot press to obtain the marine board base layer;

[0047] Step 4: Preparation of elastic adhesive layer: Epoxy resin E-44, hollow glass microspheres and additives are vacuum stirred and degassed to obtain elastic adhesive;

[0048] Step 5, Cold Pressing: Apply elastic adhesive evenly to the back of the ultra-thin marble layer, and then cold press it with the marine board base layer under set conditions to obtain the preliminary composite flooring;

[0049] Step 6, Surface abrasion resistance treatment: Spray nano-silica abrasion-resistant coating onto the marble surface of the composite flooring, and dry and cure at 80-100℃ for 2-3 hours;

[0050] Step 7: Post-processing: The composite flooring is polished and beveled to obtain ultra-thin marble-ocean slab composite flooring. After passing quality inspection, it is packaged.

[0051] Specifically, the preparation process of the ultrathin marble layer in step two is as follows:

[0052] S1.1 Mineral processing: Select Class A natural marble slabs with radioactivity ≤0.3Bq / g;

[0053] S1.2 Thinning: Five-axis water jet cutting is used, with the jet pressure controlled at 300-400mPa and the speed controlled at 180-200mm / min;

[0054] S1.3 Etching: Under etching conditions of laser power of 200-250W and scanning speed of 3-5m / s, a uniform mesh of 20-40 mesh and depth of 0.1-0.2mm is formed;

[0055] S1.4 Cutting: Finally, it is processed into thin slices of 750~800mm×750~800mm×0.5~1mm to obtain an ultra-thin marble layer for later use, in order to control the grid density and etching depth and increase the mechanical anchoring force.

[0056] The advantages are: by strictly controlling the waterjet cutting parameters and laser etching conditions, the marble is precisely thinned and gridded, which not only significantly reduces the amount of marble used, but also increases the surface roughness and mechanical anchoring force through grid etching, so that the prepared composite flooring still maintains excellent interlayer bonding strength and impact resistance under the premise of ultra-thinness.

[0057] Specifically, in step three, the marine board base layer consists of 7-9 layers of birch veneer, which is impregnated with phenolic resin for 2-4 hours, and then hot-pressed in a 0° / 90° cross pattern, with a thickness of 8-12mm. The two sides are pre-milled with double barbed locking, with a locking groove depth of 2.0-2.2mm, which can be directly spliced ​​with solid wood flooring. The height difference after splicing is ≤0.3mm, and it is ready for use.

[0058] The advantages are: through the cross-laying structure of multi-layer birch veneer and the full impregnation of phenolic resin, combined with a precise hot-pressing process, the marine board base layer has extremely high dimensional stability and mechanical strength; the pre-milled double hook locking structure design is precise, which enables the prepared composite flooring to be seamlessly spliced ​​with solid wood flooring, greatly expanding the application scenarios and installation convenience.

[0059] Specifically, the hot pressing conditions in step three are: temperature 135-145℃, pressure 1.0-1.2mPa, time 15-20min, and pressure release after cooling to ≤40℃.

[0060] Specifically, in step four, the elastic adhesive layer is made by mixing epoxy resin E-44 and hollow glass microspheres at a mass ratio of 95-100:15-25, and adding 1% to 2% of the total elastic adhesive layer mass of silane coupling agent KH-560 and 0.5% to 1% of defoamer. After curing, a buffer structure containing micro-airbags is formed with a shear strength ≥8MPa, which is then ready for use.

[0061] The advantages are: by combining epoxy resin with lightweight hollow glass microspheres and adding silane coupling agents to improve interfacial compatibility, the elastic adhesive layer can form a uniformly distributed micro-airbag buffer structure while maintaining high shear strength, effectively absorbing and dispersing impact energy, so that the prepared composite floor has excellent impact resistance and fatigue resistance.

[0062] Specifically, the vacuum stirring conditions in step four are: vacuum degree -0.09 to -0.08 mPa, rotation speed 300-400 rpm, time 8-10 min, and viscosity of the adhesive controlled at 1500-2000 mPa·s.

[0063] Specifically, the cold pressing conditions in step five are: pressure 0.5-0.8 MPa, temperature 20-25℃, curing time 48-72 h; peel strength after curing ≥2.5 N / mm.

[0064] Specifically, the post-processing procedure in step seven is as follows:

[0065] S2.1 Surface polishing: Polish step by step using 400-1000 grit diamond grinding discs until the gloss level is ≥90gU;

[0066] S2.2, Chamfering: Chamfer all four sides with a radius of 0.4-0.5mm to prevent chipping;

[0067] S2.3 Quality Inspection and Packaging: Each piece undergoes drop ball impact testing (1100-1200mm), static bending strength ≥28mPa, and formaldehyde emission ≤0.02mg / m³. 3 After passing the inspection, the products are covered with PE protective film and packed into honeycomb cardboard boxes.

[0068] The advantages are: through progressive polishing and rounded corner treatment, the surface texture and safety of the finished composite flooring can be further improved; through strict quality inspection of each piece, the mechanical properties, environmental protection and durability of the finished composite flooring are ensured to meet high standards, so that the final composite flooring has both aesthetics, safety and reliability.

[0069] Example 1 (Composite flooring A prepared using the formulation ratio and preparation conditions of the present invention)

[0070] Formula composition: natural marble slab (0.8mm, accounting for 40%), nano silica wear-resistant coating (2%), epoxy resin E-44 (5%), hollow glass microspheres (accounting for 20% of the adhesive layer), phenolic resin glue (accounting for 10% of the marine board base layer), birch veneer (7 layers × 1.5mm, accounting for 45%).

[0071] Performance parameters: flexural strength 28.5MPa, drop ball impact height 1200mm, heat deformation 0.08mm / Δ20℃, formaldehyde emission 0.018mg / m³ 3 .

[0072] Comparative Example 1 (using existing composite flooring D directly)

[0073] Structure: Traditional marble + honeycomb aluminum composite flooring (marble thickness 15mm, aluminum honeycomb core thickness 10mm).

[0074] Performance parameters: flexural strength 15.2 MPa, drop ball impact height 800 mm, heat deformation 0.35 mm / Δ20℃, formaldehyde emission 0.05 mg / m³ 3 .

[0075] Example 2 (Composite flooring B prepared using the formulation ratio and preparation conditions of the present invention)

[0076] Formula adjustments: The proportion of hollow glass microspheres was reduced to 15%, and the moisture content of birch veneer was controlled at 6%.

[0077] Performance parameters: flexural strength 27.8MPa, drop ball impact height 1180mm, thermal deformation 0.07mm / Δ20℃.

[0078] Comparative Example 2 (using existing composite flooring E directly)

[0079] Structure: Pure marine-grade flooring (covered with PVC film, 12mm thick).

[0080] Performance parameters: Mohs hardness 2, drop ball impact height 600mm, heat deformation 0.4mm / Δ20℃.

[0081] Example 3 (Composite flooring C prepared using the formulation ratio and preparation conditions of the present invention)

[0082] Formula adjustment: The proportion of nano silica coating is increased to 3%, and the epoxy value of epoxy resin E-44 is 0.51mol / 100g.

[0083] Performance parameters: Surface abrasion resistance ≥7500r / Taber, bending strength 29.1MPa, drop ball impact height 1220mm.

[0084] Comparative Example 3 (using existing composite flooring F directly)

[0085] Structure: Traditional cement mortar paving marble tiles (30mm thick).

[0086] Performance parameters: Weight 35kg / m 2 Installation cycle: 7 days / 100m 2 It has no elastic buffer layer.

[0087] The performance of the composite flooring in the examples and comparative examples was tested, and the test data are shown in Table 2 below:

[0088] Table 2

[0089]

[0090]

[0091] From Table 2, we can obtain:

[0092] (1) The mechanical properties and thermal stability of the composite flooring of the present invention far exceed those of traditional composite flooring: the bending strength of Examples 1-3 is ≥27.8MPa, the drop ball impact height is ≥1180mm, and the thermal deformation is ≤0.08mm / Δ

[0093] The impact resistance of the composite flooring was 20℃; while the bending strength of Comparative Example 1 (traditional marble + honeycomb aluminum base) was only 15.2MPa, the impact height of the dropped ball was 800mm, and the heat deformation was 0.35mm / Δ20℃; the impact height of the dropped ball of Comparative Example 2 (pure marine board flooring) was only 600mm, and the heat deformation was 0.4mm / Δ20℃. This shows that the present invention, through the toughening of the ultra-thin marble layer mesh etching and the micro-airbag buffer design of the elastic adhesive layer, can significantly improve the impact resistance and structural stability of the composite flooring, thereby effectively solving the problems of easy deformation and poor impact resistance of traditional composite flooring.

[0094] (2) The composite flooring of this invention achieves ultra-thinness and lightweight, which is significantly better than traditional installation methods: the thickness of Examples 1-3 is ≤12.2mm, and the weight per unit area is ≤28.5kg / m². 2 Comparative Example 1 has a thickness of 25mm and a weight of 38kg / m. 2 Comparative Example 3 (traditional cement mortar paving of marble tiles) 30mm thick, 35kg / m 2 Based on the above data, this invention significantly reduces the thickness and weight of the flooring while ensuring performance through ultra-thin marble cutting (0.5-1mm) and lightweight design of the marine board base layer, thereby reducing the building's load-bearing capacity and avoiding the heavy problems of traditional paving.

[0095] (3) The composite flooring of the present invention has significant advantages in terms of environmental protection and installation efficiency: the formaldehyde emission of Examples 1-3 is ≤0.019mg / m³. 3 It meets ENF environmental standards and installation takes only 2 days per 100m. 2 Comparative Example 1: Formaldehyde release 0.05 mg / m³ 3 Installation time: 7 days / 100m 2 The formaldehyde release of Comparative Example 2 was 0.03 mg / m³. 3 Installation time: 3 days / 100m 2 Comparative Example 3: Formaldehyde release 0.08 mg / m³ 3 Installation time: 7 days / 100m 2 The above comparative data shows that the present invention uses low formaldehyde raw materials (such as phenolic resin glue with free formaldehyde ≤0.1%) and a snap-fit ​​splicing structure, which can not only ensure the safety of the indoor environment, but also significantly shorten the installation cycle and ultimately improve construction efficiency.

[0096] In summary, the ultra-thin marble-ocean slab composite flooring and its preparation method provided by this invention, through the mesh etching and toughening treatment of the ultra-thin marble layer, the buffer design of the elastic adhesive layer containing micro-airbags, and the interlocking splicing structure of the highly stable ocean slab base layer, successfully achieves ultra-thin (≤13mm), lightweight (weight reduction of more than 60%), high impact resistance (drop ball impact ≥1200mm), seamless splicing (height difference ≤0.3mm), rapid installation, and excellent thermal stability of the flooring. At the same time, the preparation process of this invention is green and environmentally friendly, the formaldehyde emission of the finished composite flooring reaches the ENF level, and it significantly reduces the amount of marble used and the overall cost, making it suitable for various scenarios in high-end residential and commercial spaces.

[0097] 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. An ultra-thin marble-oceanic board composite floor, characterized in that, The composite floor is composed of an ultra-thin marble layer, an elastic adhesive layer and an ocean plate base layer from top to bottom, and the raw materials and their mass percentages are as follows: natural marble plate accounts for 35-45% of the total mass of the composite floor; nano-silicon dioxide wear-resistant coating accounts for 1-3% of the total mass of the composite floor; epoxy resin E-44 accounts for 4-6% of the total mass of the composite floor; hollow glass microbeads account for 15-25% of the mass of the adhesive layer; phenolic resin glue accounts for 8-12% of the mass of the ocean plate base layer; and birch veneer accounts for 45-55% of the total mass of the composite floor.

2. The ultra-thin marble-oceanic plank composite floor according to claim 1, characterized in that: The nano-silica wear-resistant coating is a silica sol system with a solid content of ≥30%; the epoxy resin E-44 has an epoxy value of 0.44-0.51 mol / 100 g; the hollow glass microbeads have a particle size of 10-50 um and a density of 0.15-0.25 g / cm 3 ; the phenolic resin glue has a solid content of 45%-50% and free formaldehyde ≤0.1%; the birch veneer has a thickness of 1.2-1.8 mm and a moisture content of 6%-8%.

3. A method of manufacturing an ultra-thin marble-oceanic board composite floor, characterized by, The raw materials and their mass percentages of the ultra-thin marble-ocean plate composite floor according to claim 1 are prepared by the following preparation steps: Step one, prepare natural marble plate, nano-silicon dioxide wear-resistant coating, epoxy resin E-44, hollow glass microbeads, phenolic resin glue and birch veneer according to the mass percentages; Step two, ultra-thin marble layer preparation: cut the natural marble plate into 750-800mm×750-800mm×0.5-1mm thin slices using a five-axis water jet to obtain the ultra-thin marble layer; Step three, ocean plate base layer preparation: dry the birch veneer to a moisture content of 6-8%, impregnate it with phenolic resin, cross-laminate at 0° / 90° and hot-press to obtain the ocean plate base layer; Step four, elastic adhesive layer preparation: vacuum stir and defoam the epoxy resin E-44, hollow glass microbeads and additives to obtain the elastic glue; Step five, cold pressing: evenly coat the elastic glue on the back of the ultra-thin marble layer, cold-press it with the ocean plate base layer under the set conditions to obtain the initially formed composite floor; Step six, surface wear-resistant treatment: spray nano-silicon dioxide wear-resistant coating on the marble surface of the composite floor and dry and cure it at 80-100℃ for 2-3h; Step seven, post-processing: polish and chamfer the surface of the composite floor to obtain the ultra-thin marble-ocean plate composite floor, which is packaged after quality inspection.

4. The preparation method of the ultra-thin marble-ocean plate composite floor according to claim 3, characterized in that: The ultra-thin marble layer preparation process in step two is as follows: S1.1, ore dressing: select A-class natural marble plate with radioactivity ≤0.3Bq / g; S1.2, thinning: cut using a five-axis water jet with jet pressure controlled at 300-400mPa and speed controlled at 180-200mm / min; S1.3, etching: form a uniform grid with 20-40 mesh and 0.1-0.2mm depth under etching conditions of laser power 200-250W and scanning speed 3-5m / s; S1.4, cutting: finally process into 750-800mm×750-800mm×0.5-1mm thin slices to obtain the ultra-thin marble layer.

5. The preparation method of the ultra-thin marble-ocean plate composite floor according to claim 3, characterized in that: The ocean plate base layer in step three is 7-9 layers of birch veneer, which is impregnated with phenolic resin glue for 2-4h, cross-laminated at 0° / 90° and hot-pressed to form a thickness of 8-12mm; the two sides are pre-milled with double inverted hook locks with a groove depth of 2.0-2.2mm, which can be directly spliced with solid wood floors with a height difference ≤0.3mm after splicing.

6. The preparation method of the ultra-thin marble-ocean plate composite floor according to claim 5, characterized in that: The hot pressing condition in the third step is: temperature 135-145℃, pressure 1.0-1.2mPa, time 15-20min, and the pressure is unloaded after cooling to ≤40℃.

7. The preparation method of the ultra-thin marble-ocean plate composite floor according to claim 3, characterized in that: The elastic adhesive layer in the fourth step is formed by mixing epoxy resin E-44 and hollow glass microbeads at a mass ratio of 95-100:15-25, and adding 1%-2% of silane coupling agent KH-560 and 0.5%-1% of defoaming agent based on the total mass of the elastic adhesive layer, and the shear strength of the buffer structure containing micro-cells formed after curing is ≥8MPa.

8. The preparation method of the ultra-thin marble-ocean plate composite floor according to claim 3, characterized in that: The vacuum stirring condition in the fourth step is: vacuum degree -0.09 to -0.08mPa, rotation speed 300-400rpm, time 8-10min, and the viscosity of the glue solution is controlled at 1500-2000mPa·s.

9. The preparation method of the ultra-thin marble-ocean plate composite floor according to claim 3, characterized in that: The cold pressing condition in the fifth step is: pressure 0.5-0.8mPa, temperature 20-25℃, and curing time 48-72h; and the peeling strength after curing is ≥2.5N / mm.

10. The method of claim 3, wherein the super-thin marble-oceanic plate composite floor is prepared by the steps of: The post-processing treatment process in the seventh step is: ​ S2.1, surface polishing: polishing with 400-1000 mesh diamond abrasive disc step by step until the glossiness is ≥90gU; S2.2, chamfering: chamfering the four edges with a round angle of R0.4-0.5mm to prevent edge collapse; S2.3, quality inspection package: each piece is subjected to drop ball impact 1100-1200mm, static bending strength ≥28mPa, formaldehyde release ≤0.02mg / m 3 After detection, PE protective film is covered and the product is packed in honeycomb carton.

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