EB-cured polypropylene film veneer composite floor and production process thereof

Abstract

The invention belongs to the technical field of ground paving materials, and relates to an EB cured polypropylene film veneer composite floor which comprises an improved three-layer solid wood composite floor base body layer. According to the improved three-layer solid wood composite floor base body layer, a base material bottom layer, a base material core layer and a base material surface layer are assembled into a sandwich type structure from bottom to top according to longitudinal, transverse and longitudinal wood grains in a staggered mode. The base material core layer is composed of a plurality of battens which are laterally spliced; a gluing layer is arranged between the surface decoration layer and the base material surface layer; and the surface decoration layer is an EB cured polypropylene film. The invention further discloses a production process of the floor. The floor disclosed by the invention is a substitute product of a solid wood board, can effectively reduce the consumption of wood, and solves the tension situation of shortage of forest resources so as to protect natural resources; compared with an existing composite floor and the prior art, the composite floor is simple in process, more environmentally friendly and relatively low in comprehensive cost.

Description

Technical Field

[0001] This invention belongs to the field of floor paving materials technology, and relates to solid wood composite flooring, and more particularly to an EB-cured polypropylene film-faced composite flooring and its production process. Background Technology

[0002] Multi-layer engineered wood flooring is a popular decorative material in the furniture and building materials industry. However, with the scarcity of forest resources, the availability of beautifully patterned solid wood veneers is decreasing. How to effectively improve the comprehensive utilization rate of timber resources, alleviate the current tight supply of timber resources, respond to the national green development policy, implement the dual-carbon development strategy, and strengthen my country's ecological civilization construction are urgent research topics. Three-layer engineered wood flooring uses solid wood veneer or plywood as the top layer, solid wood veneer as the core layer, and veneer as the bottom layer. The veneer is relatively thick, at least 2mm, requiring high-quality surface materials.

[0003] Chinese patent CN101100897A discloses a production process for a three-layer solid wood composite floor with a fir core. It uses fir instead of pine, solving the problem of warping and deformation that exists in existing technologies using fir as the core of three-layer solid wood composite flooring. This reduces the degree and rate of deformation, improves product quality, and has good economic and social benefits. Chinese patent CN213710202U discloses a novel three-layer solid wood composite flooring, including a composite flooring body. The composite flooring body includes a panel, which consists of an upper panel and a lower panel. The lower panel is composed of multiple sets of spliced ​​panels. Both the upper and lower surfaces of the upper panel have transverse grain. This new type of three-layer solid wood composite flooring uses a method of joining the first and second connecting plates to assemble the two sets of composite flooring bodies. This reduces the amount of adhesive used, reduces the amount of harmful substances remaining, speeds up the splicing process, and improves work efficiency. The first and second connecting plates are fixed by diamond-shaped fixing rods, which enhances the firmness of the splicing of the two sets of composite flooring bodies. The fixing plates are fixed by insert blocks, ensuring the firmness of the diamond-shaped fixing rods between the first and second connecting plates. Summary of the Invention

[0004] To overcome the shortcomings of existing technologies, this invention discloses an EB-cured polypropylene film-faced composite flooring. This novel composite board, formed by combining an improved three-layer solid wood composite flooring matrix with an EB-cured polypropylene film, inherits the elegant and natural characteristics of solid wood. From the perspective of forest resource protection, it is a substitute for solid wood, effectively reducing timber consumption. It also possesses excellent waterproofness, water resistance, stability, decorative properties, and durability.

[0005] Technical solution

[0006] An EB-cured polypropylene film-faced composite flooring includes an improved three-layer solid wood composite flooring substrate layer, wherein the improved three-layer solid wood composite flooring substrate layer is assembled from bottom to top into a sandwich structure consisting of a substrate bottom layer, a substrate core layer, and a substrate surface layer with longitudinal, transverse, and longitudinal wood grain patterns; the substrate core layer is composed of several side-jointed strips; an adhesive layer is provided between the surface decoration layer and the substrate surface layer; the surface decoration layer is an EB-cured polypropylene film.

[0007] In a preferred embodiment of the present invention, the thickness of the improved three-layer solid wood composite flooring substrate layer is 10-18 mm.

[0008] In a preferred embodiment of the present invention, the thickness of the substrate bottom layer is 0.6-2.0 mm, the moisture content is 8-12%, and it is made of birch, pine, poplar, or other tree species.

[0009] In a preferred embodiment of the present invention, the gap between the strips of the substrate core layer is ≤1mm, and the wood is of species such as pine, poplar, or fir.

[0010] Furthermore, the width of the strip is 20-50 mm, the thickness is 8-13 mm, and the moisture content is 8-12%.

[0011] Furthermore, waste wood, small-sized firewood or fast-growing timber and soft broad-leaved wood can be used to process into strips, which can then be spliced ​​together with adhesive tape or hot melt adhesive.

[0012] In a preferred embodiment of the present invention, the thickness of the surface layer of the substrate is 1-3 mm, the moisture content is 8-12%, and it is a hard hardwood such as birch or maple.

[0013] Furthermore, high-quality hardwood veneers are selected and rotary-cut or sawn to produce veneers that are hard, resistant to pressure, and have beautiful textures and uniform color.

[0014] In a preferred embodiment of the present invention, the thickness of the surface decorative layer is 0.27±0.05mm.

[0015] Furthermore, the EB-cured polypropylene film is a film made from polypropylene using an electron beam curing process. Its surface not only includes wood grain but also paint, special flatness, and antique effects, combining wood grain and paint effects to create a composite of natural wood grain, antique effect, and paint treatment effect.

[0016] In a preferred embodiment of the present invention, the adhesive layer has a thickness of 0.1 to 0.2 mm and is formed by curing polyurethane resin hot melt adhesive, which overcomes the problem that EB-cured polypropylene film is prone to surface defects on rough wood surfaces.

[0017] Another objective of this invention is to disclose the production process of the above-mentioned EB-cured polypropylene film-faced composite flooring.

[0018] A manufacturing process for EB-cured polypropylene film-faced composite flooring includes the following steps:

[0019] (1) Improved preparation of the matrix layer for three-layer solid wood composite flooring:

[0020] a. Material preparation; prepare the front panel, base plate, and core board;

[0021] b. Core board assembly: The core board strips are laid out in parallel and strung together on the core board stringing machine to form core boards of the required specifications. Then, hot melt adhesive is used to assemble the core boards.

[0022] c. Substrate layer assembly: Apply adhesive to both the front and back panels on one side using melamine-modified urea-formaldehyde resin adhesive. The adhesive application rate for the back panel is 100–200 g / m². 2 The adhesive application rate for the panel fabric is 130–200 g / m². 2 After applying the adhesive, the surface panel, core panel, and base panel are arranged in a staggered pattern according to the wood grain, running longitudinally, laterally, and vertically.

[0023] The blanks are assembled according to a sandwich structure.

[0024] d. Cold pressing and hot pressing bonding: After assembly, the slab is first cold-pressed in a cold press for 30–90 minutes.

[0025] Pressure 0.8–2 MPa; then hot pressing at 100–120℃ for 1–1.5 min / mm.

[0026] Pressure 0.8–2 MPa;

[0027] e. Aging for health benefits; aging time is 7–15 days;

[0028] (2) Lamination: After sanding and dust removal, the surface of the improved three-layer solid wood composite flooring substrate is coated with polyurethane resin hot melt adhesive at a coating amount of 45-65 g / m². 2 Set the bonding spacing and bond the EB-cured polypropylene film with natural wood grain, antique effect, and paint finish to the substrate layer in one go.

[0029] (3) Balancing and curing: After the boards are covered, they are quickly cut, stacked face to face, and placed in a balancing chamber for curing for ≥7 days;

[0030] (4) Cutting: After the substrate has been balanced and cured, it is cut into strips and the back is sanded to fix the thickness to form floor strips;

[0031] (5) Molding: tongue and groove joints are formed on the floor strips;

[0032] (6) Apply chamfering paint: Spray chamfering paint on the chamfered corners of the floor to match the color of the board surface, so that they are coordinated and uniform;

[0033] (7) Sealing with wax: Spray plant-based sound-absorbing wax onto the floor's locking tongue and groove areas. The application amount should be adjusted according to the type of locking mechanism, at 20-30 g / m². 2 ;

[0034] (8) Finished product packaging: After passing the quality QC inspection, the finished product is packaged directly.

[0035] This invention employs a polyurethane hot melt adhesive bonding process to bond the surface layer to the substrate. The bonding speed is fast during bonding, enabling assembly line production. No substances harmful to humans or the environment are released during or after the bonding process. This allows the prepared EB-cured polypropylene film-faced composite flooring to inherit the elegant and natural characteristics of solid wood boards, and possesses excellent waterproofness, water resistance, stability, decorative properties, and durability.

[0036] Beneficial effects

[0037] This invention discloses an EB-cured polypropylene film-faced composite flooring and its production process. A polypropylene film with wood grain, antique effect, and paint finish, cured using the ElectronBeam process, is adhered to the surface of a flooring substrate to create an EB-cured polypropylene film-faced multi-layer composite flooring. It inherits the elegant and natural characteristics of solid wood panels. From the perspective of forest resource protection, it is a substitute for solid wood panels, effectively reducing timber consumption and alleviating the tension of forest resource scarcity, thus protecting natural resources. Compared with existing composite flooring and technologies, the process is simpler, more environmentally friendly, and has a relatively lower overall cost. Attached Figure Description

[0038] Figure 1 Schematic diagram of EB-cured polypropylene film-faced composite flooring.

[0039] Figure 2 Schematic diagram of the core layer arrangement of the substrate.

[0040] The components are labeled as follows: (1) surface decoration layer, (2) adhesive layer, (3) improved three-layer solid wood composite flooring base layer, (4) base material bottom layer, (5) base material core layer, and (6) base material surface layer. Detailed Implementation

[0041] The present invention will be described in detail below with reference to embodiments, so that those skilled in the art can better understand the present invention, but the present invention is not limited to the following embodiments.

[0042] Example 1

[0043] An EB-cured polypropylene film-faced composite flooring includes an improved three-layer solid wood composite flooring substrate layer 3, wherein the improved three-layer solid wood composite flooring substrate layer 3 is assembled from bottom to top into a sandwich structure consisting of a substrate bottom layer 4, a substrate core layer 5, and a substrate surface layer 6 with longitudinal, transverse, and longitudinal wood grain patterns; the substrate core layer 5 is composed of several side-jointed strips; an adhesive layer 2 is provided between the surface decorative layer 1 and the substrate surface layer 6; the surface decorative layer 1 is an EB-cured polypropylene film.

[0044] Example 2

[0045] An EB-cured polypropylene film-faced composite flooring includes an improved three-layer solid wood composite flooring substrate layer 3. The improved three-layer solid wood composite flooring substrate layer 3, from bottom to top, consists of a substrate bottom layer 4, a substrate core layer 5, and a substrate surface layer 6, arranged in a sandwich-like structure with longitudinal, transverse, and longitudinal wood grain patterns, and has a thickness of 10–18 mm. The substrate core layer 5 is composed of several side-jointed strips. An adhesive layer 2 is provided between the surface decorative layer 1 and the substrate surface layer 6. The surface decorative layer 1 is an EB-cured polypropylene film with a thickness of 0.27 ± 0.05 mm.

[0046] Example 3

[0047] An EB-cured polypropylene film-faced composite flooring includes an improved three-layer solid wood composite flooring base layer 3. The improved three-layer solid wood composite flooring base layer 3, from bottom to top, consists of a substrate bottom layer 4, a substrate core layer 5, and a substrate surface layer 6, arranged with longitudinal, transverse, and longitudinal wood grain patterns in a sandwich-like structure, with a thickness of 10–18 mm. The substrate bottom layer 4 has a thickness of 0.6–2.0 mm, a moisture content of 8–12%, and is made of birch, pine, poplar, or other wood species. The substrate core layer 5 is composed of several side-jointed strips with gaps ≤1 mm between the strips, and is made of pine, poplar, fir, or other wood species. The strips have a width of 20–50 mm, a thickness of 8–13 mm, and a moisture content of 8–12%. An adhesive layer 2 is provided between the surface decorative layer 1 and the substrate surface layer 6. The surface decorative layer 1 is an EB-cured polypropylene film with a thickness of 0.27 ± 0.05 mm.

[0048] Example 4

[0049] An EB-cured polypropylene film-faced composite flooring includes an improved three-layer solid wood composite flooring base layer 3. The improved three-layer solid wood composite flooring base layer 3, from bottom to top, consists of a substrate bottom layer 4, a substrate core layer 5, and a substrate surface layer 6, arranged in a sandwich-like structure with longitudinal, transverse, and longitudinal wood grain patterns, and has a thickness of 10–18 mm. The substrate bottom layer 4 has a thickness of 0.6–2.0 mm, a moisture content of 8–12%, and is made of birch, pine, poplar, or other wood species. The substrate core layer… 5 is composed of several side-jointed strips with gaps between the strips ≤1mm, made of pine, poplar, fir, or other tree species. The strips are 20-50mm wide, 8-13mm thick, and have a moisture content of 8-12%. An adhesive layer 2 is provided between the surface decorative layer 1 and the substrate surface layer 6. The surface decorative layer 1 is an EB-cured polypropylene film with a thickness of 0.27±0.05mm. The substrate surface layer 6 has a thickness of 1-3mm, a moisture content of 8-12%, and is made of hardwoods such as birch and maple.

[0050] Example 5

[0051] An EB-cured polypropylene film-faced composite flooring includes an improved three-layer solid wood composite flooring base layer 3. The improved three-layer solid wood composite flooring base layer 3, from bottom to top, consists of a substrate bottom layer 4, a substrate core layer 5, and a substrate surface layer 6, arranged with longitudinal, transverse, and longitudinal wood grain patterns in a sandwich-like structure, with a thickness of 10–18 mm. The substrate bottom layer 4 has a thickness of 0.6–2.0 mm, a moisture content of 8–12%, and is made of birch, pine, poplar, or other wood species. The substrate core layer 5 is composed of several side-jointed strips, with the strips... The gaps are ≤1mm, and the wood is of species such as pine, poplar, and fir. The width of the strips is 20-50mm, the thickness is 8-13mm, and the moisture content is 8-12%. An adhesive layer 2 is provided between the surface decorative layer 1 and the substrate surface layer 6. The adhesive layer 2 is 0.1-0.2mm thick and is made of polyurethane resin hot melt adhesive. The surface decorative layer 1 is an EB-cured polypropylene film with a thickness of 0.27±0.05mm. The substrate surface layer 6 is 1-3mm thick, has a moisture content of 8-12%, and is made of hardwood such as birch and maple.

[0052] Example 6

[0053] A manufacturing process for EB-cured polypropylene film-faced composite flooring includes the following steps:

[0054] (1) Improved preparation of the matrix layer for three-layer solid wood composite flooring:

[0055] a. Material preparation; prepare the front panel, base plate, and core board;

[0056] b. Core board assembly: The core board strips are laid out in parallel and strung together on the core board stringing machine to form core boards of the required specifications. Then, hot melt adhesive is used to assemble the core boards.

[0057] c. Substrate layer assembly: Apply adhesive to both the front and back panels on one side using melamine-modified urea-formaldehyde resin adhesive. The adhesive application rate for the back panel is 100–200 g / m². 2 The adhesive application rate for the panel fabric is 130–200 g / m². 2 After applying the adhesive, the surface panel, core panel, and base panel are arranged in a staggered pattern according to the wood grain, running longitudinally, laterally, and vertically.

[0058] The blanks are assembled according to a sandwich structure.

[0059] d. Cold pressing and hot pressing bonding: After assembly, the slab is first cold-pressed in a cold press for 30–90 minutes.

[0060] Pressure 0.8–2 MPa; then hot pressing at 100–120℃ for 1–1.5 min / mm.

[0061] Pressure 0.8–2 MPa;

[0062] e. Aging for health benefits; aging time is 7–15 days;

[0063] (2) Lamination: After sanding and dust removal, the surface of the improved three-layer solid wood composite flooring substrate is coated with polyurethane resin hot melt adhesive at a coating amount of 45-65 g / m². 2 Set the bonding spacing and bond the EB-cured polypropylene film with natural wood grain, antique effect, and paint finish to the substrate layer in one go.

[0064] (3) Balancing and curing: After the boards are covered, they are quickly cut, stacked face to face, and placed in a balancing chamber for curing for ≥7 days;

[0065] (4) Cutting: After the substrate has been balanced and cured, it is cut into strips and the back is sanded to fix the thickness to form floor strips;

[0066] (5) Molding: tongue and groove joints are formed on the floor strips;

[0067] (6) Apply chamfering paint: Spray chamfering paint on the chamfered corners of the floor to match the color of the board surface, so that they are coordinated and uniform;

[0068] (7) Sealing with wax: Spray plant-based sound-absorbing wax onto the floor's locking tongue and groove areas. The application amount should be adjusted according to the type of locking mechanism, at 20-30 g / m². 2 ;

[0069] (8) Finished product packaging: After passing the quality QC inspection, the finished product is packaged directly.

[0070] The above description is merely an embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent structural or procedural transformations made using the present invention specification, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of the present invention.

Claims

1. An EB-cured polypropylene film-faced composite flooring, comprising an improved three-layer solid wood composite flooring substrate layer (3), characterized in that: The improved three-layer solid wood composite flooring base layer (3) consists of a base layer bottom layer (4), a base core layer (5), and a base surface layer (6) arranged in a sandwich structure with longitudinal, transverse, and longitudinal wood grain patterns from bottom to top; the base core layer (5) is composed of several side-jointed strips; an adhesive layer (2) is provided between the surface decoration layer (1) and the base surface layer (6), and the surface decoration layer (1) is an EB-cured polypropylene film.

2. The EB-cured polypropylene film-faced composite flooring according to claim 1, characterized in that: The thickness of the improved three-layer solid wood composite flooring base layer (3) is 10-18 mm.

3. The EB-cured polypropylene film-faced composite flooring according to claim 1, characterized in that: The thickness of the substrate bottom layer (4) is 0.6-2.0 mm, the moisture content is 8-12%, and it is made of birch, pine or poplar.

4. The EB-cured polypropylene film-faced composite flooring according to claim 1, characterized in that: The gap between the strips of the core layer (5) of the substrate is ≤1mm, and it is made of pine, poplar or fir.

5. The EB-cured polypropylene film-faced composite flooring according to claim 1, characterized in that: The strips are 20-50 mm wide, 8-13 mm thick, and have a moisture content of 8-12%.

6. The EB-cured polypropylene film-faced composite flooring according to claim 1, characterized in that: The thickness of the substrate surface layer (6) is 1-3 mm, the moisture content is 8-12%, and it is made of birch or maple.

7. The EB-cured polypropylene film-faced composite flooring according to claim 1, characterized in that: The surface decorative layer (1) has a thickness of 0.27±0.05mm.

8. The EB-cured polypropylene film-faced composite flooring according to claim 1, characterized in that: The coating layer (2) has a thickness of 0.1 to 0.2 mm and is formed by curing polyurethane resin hot melt adhesive.

9. A process for producing EB-cured polypropylene film-faced composite flooring as described in any one of claims 1-8, characterized in that, Includes the following steps: (1) Improved preparation of the matrix layer for three-layer solid wood composite flooring: a. Material preparation; prepare the front panel, base plate, and core board; b. Core board assembly: The core board strips are laid out in parallel and strung together on the core board stringing machine to form core boards of the required specifications. Then, hot melt adhesive is used to assemble the core boards. c. Substrate layer assembly: Apply adhesive to both the front and back panels on one side using melamine-modified urea-formaldehyde resin adhesive. The adhesive application rate for the back panel is 100–200 g / m². 2 The adhesive application rate for the panel fabric is 130–200 g / m². 2 After applying the glue, the top panel, core panel, and bottom panel are arranged in a staggered pattern according to the wood grain, forming a sandwich structure. d. Cold pressing and hot pressing bonding: After assembly, the slab is first cold pressed in a cold press for 30-90 minutes at a pressure of 0.8-2 MPa; then it is hot pressed at a temperature of 100-120℃ for 1-1.5 minutes / mm at a pressure of 0.8-2 MPa. e. Aging for health benefits; aging time is 7–15 days; (2) Application: After sanding and dust removal, the surface of the improved three-layer solid wood composite flooring substrate is coated with polyurethane resin hot melt adhesive at a coating amount of 45-65 g / m². 2 Set the bonding spacing and bond the EB-cured polypropylene film with natural wood grain, antique effect, and paint finish to the substrate layer in one go. (3) Balancing and curing: After the boards are covered, they are quickly cut, stacked face to face, and placed in a balancing room for curing for ≥7 days; (4) Cutting: After the substrate has been balanced and cured, it is cut into strips and the back is sanded to fix the thickness to form floor strips; (5) Molding: tongue and groove joints are made for the floor strips; (6) Apply chamfering paint: Spray chamfering paint on the chamfered corners of the floor to match the color of the board surface and make them coordinated and uniform; (7) Sealing with wax: Spray plant-based sound-absorbing wax onto the floor's locking groove. The amount of wax applied should be adjusted according to the type of locking mechanism, ranging from 20 to 30 g / m². 2 ; (8) Finished product packaging: After passing the quality QC inspection, the finished product is packaged directly.

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