Special-shaped magnetic suspension floor

Abstract

The invention relates to the technical field of floors, and discloses a special-shaped magnetic suspension floor, the special-shaped magnetic suspension floor comprises a bottom plate, canvas, a base material, magnetic cloth and a floor, the base material comprises polyvinyl chloride (PVC) resin, a plasticizer, calcium carbonate, a calcium-zinc stabilizer and carbon black, the bottom plate, the canvas, the base material, the magnetic cloth and the floor are put into a hot press for hot pressing, the temperature of a first temperature section of the hot press is 150 DEG C, the time is 1200 s, and the temperature of a second temperature section of the hot press is 150 DEG C; the temperature of a first pressing machine temperature section is 150 DEG C, the pressure is 40 bar, the temperature of a second pressing machine temperature section is 150 DEG C, the time is 1300 s, the pressure is 60 bar, the temperature of a third pressing machine temperature section is 150 DEG C, the time is 240 s, the pressure is 80 bar, the time of passing through a cooling device is 2000 s, the pressure is 120 bar, a magnetic suction cushion layer is manufactured, the magnetic suction cushion layer manufactured through hot pressing cooling can be used for convenient and fast attachment use, and the suspension floor is simple in installation mode and convenient to install. The suspension floor can be installed without complex tools, the installation speed of the suspension floor is high, style transformation and replacement of the suspension floor are facilitated, and therefore the convenience of upgrading of the suspension floor is improved.

Description

Technical Field

[0001] This invention relates to the field of flooring technology, specifically to irregularly shaped magnetic levitation flooring. Background Technology

[0002] Suspended interlocking flooring, also known as modular sports flooring, is a fourth-generation sports flooring material. The finished product comes in blocks and can be directly laid on cement and asphalt base surfaces without adhesive. Each block is connected by a unique interlocking system, making installation very simple and allowing for easy disassembly. Suspended interlocking flooring uses mature, high-strength, environmentally friendly polypropylene material, effectively solving the problem of thermal expansion and contraction while maintaining stable surface friction. Anti-UV additives are incorporated into each block, ensuring the flooring will not fade even under long-term sunlight exposure. The suspended structural design, combined with a sturdy reinforced support structure, creates excellent vertical shock absorption. The non-slip surface effectively prevents sports injuries, and good ball rebound and speed ensure superior athletic performance. It is ideal for laying high-performance basketball courts, tennis courts, five-a-side football fields, roller skating rinks, table tennis courts, and multi-functional courts for volleyball and badminton. The aforementioned limitations severely restrict further improvements to irregularly shaped magnetic levitation flooring, resulting in a lack of strong three-dimensionality, layering, ease of installation, and loss of the original flooring's inherent safety, durability, environmental friendliness, and health benefits. Furthermore, it fails to combine artistic appeal and auspicious symbolism, making irregularly shaped levitation plastic flooring more aesthetically pleasing to Chinese consumers particularly problematic in the following aspects: (1) The installation of suspended floors is complicated. It requires complicated tools and is slow to install. It is inconvenient to modify or change the style of the suspended floors, thus reducing the convenience of upgrading the suspended floors. (2) The disassembly of suspended floors is complicated. It cannot be reused in different scenarios and damaged suspended floors cannot be repaired locally, thus reducing the service life of the suspended floors. (3) The suspended floors cannot be operated manually. The labor cost of operating suspended floors is high and it is not possible to clean the suspended floors without obstacles, thus reducing the convenience of operating suspended floors. Summary of the Invention

[0003] The purpose of this invention is to provide irregularly shaped magnetic suspension flooring to solve the problems mentioned in the background art above: (1) the suspension flooring is complicated to install, requires complicated tools, is slow to install, and is inconvenient to modify or change the style of the suspension flooring, thus reducing the convenience of upgrading the suspension flooring; (2) the suspension flooring is complicated to disassemble, cannot be reused in different scenarios, and cannot be partially repaired, thus reducing the service life of the suspension flooring; (3) the suspension flooring cannot be operated manually, the labor cost of operating the suspension flooring is high, and it is not possible to clean the suspension flooring without obstacles, thus reducing the convenience of operating the suspension flooring. To address the issues of complex installation methods for existing suspended flooring, which require sophisticated tools, are slow to install, and hinder style modifications and upgrades, this invention provides a non-standard magnetic suspended flooring. The core concept involves hot-pressing a base plate, canvas, substrate, magnetic cloth, and flooring together in a press. The press operates at three temperature zones: 150°C for 1200 seconds at 40 bar; 150°C for 1300 seconds at 60 bar; and 150°C for 240 seconds at 80 bar. A cooling process is then performed for 2000 seconds at 120 bar, creating a magnetic pad that can be easily attached using the hot-pressed and cooled magnetic pad. This simplified installation method eliminates the need for complex tools, allows for rapid installation, and facilitates style modifications and upgrades, thus significantly improving the ease of upgrading suspended flooring.

[0004] To achieve the above objectives, the present invention provides the following technical solution: an irregularly shaped magnetic levitation floor, comprising a base plate, a canvas, a substrate, magnetic cloth, and a floor, wherein the substrate comprises polyvinyl chloride (PVC) resin, plasticizer, calcium carbonate, calcium-zinc stabilizer, and carbon black.

[0005] Preferably, the floor is made of high-density polypropylene.

[0006] The preparation method of the irregularly shaped magnetic levitation floor includes the following steps: Step 1: Pre-fabrication of substrate: Polyvinyl chloride (PVC) resin, plasticizer, calcium carbonate, calcium zinc stabilizer and carbon black are fed into a high-speed mixer in proportion and stirred and mixed. Step 2: Preparation of the substrate surface layer: The mixed polyvinyl chloride (PVC) resin, plasticizer, calcium carbonate, calcium zinc stabilizer and carbon black are fed into the first roll of the open mill for preparation, then into the second roll of the open mill for preparation, then into the first sheeting roll for preparation, then into the second sheeting roll for preparation, then into the third sheeting roll for preparation, then into the fourth sheeting roll for preparation, then into the fourth sheeting roll for preparation, then into the fourth roll for preparation, then into the fourth roll for preparation, then into the fourth roll for preparation, then into the fourth roll for preparation, then into the fourth roll for preparation, then into the fifth roll for preparation, and finally into the fourth roll for preparation, then into the fifth roll for preparation, and finally into the fifth roll for preparation to form the surface layer substrate. Step 3: Hot pressing process preparation: Place the embossed plate, canvas, PVC wear-resistant layer, face film, substrate, magnetic cloth and base pattern plate into a hot press and press them together. After cooling, the magnetic surface layer is formed. Step 4: Magnetic Surface Layer Design: The irregularly shaped magnetic surface layer is prepared using CAD design, software programming, and CNC engraving. Step 5: Preparation of magnetic padding layer: Place the base plate, canvas, substrate, magnetic cloth and base plate into a hot press and press them together. Cool to form a magnetic padding layer; cut the padding layer to the appropriate size according to the laying requirements. Step Six: Flooring Installation: Lay the magnetic pads with the magnetic side facing up in a staggered pattern. Then, install the flooring on the flat pads according to the shape of the irregular surface layer.

[0007] Preferably, in step one, the polyvinyl chloride (PVC) resin comprises 80 to 120 parts, the plasticizer comprises 15 to 25 parts, the calcium carbonate comprises 250 to 320 parts, the calcium-zinc stabilizer comprises 2 to 6 parts, and the carbon black comprises 1 to 3 parts.

[0008] Preferably, the thickness of the magnetic cloth in step three is between 0.3 and 1.0 mm.

[0009] Preferably, in step two, the temperature of the high-speed mixer is 90±15℃, the temperature of the open mill head roll is 160±25℃, the main machine speed is 50±10, the temperature of the open mill second roll is 160±25℃, the main machine speed is 50±10, the temperature of the sheeting first roll is 180±25℃, the main machine speed is 20±10, the temperature of the sheeting second roll is 170±25℃, the main machine speed is 25±10, the temperature of the sheeting third roll is 150±25℃, the main machine speed is 35±15, and the temperature of the sheeting fourth roll is 150±25℃, the main machine speed is 45±15.

[0010] Preferably, in step two, the rotation speed of the lead-out roller is 45±15 and the rotation speed of the cooling roller is 50±15.

[0011] Preferably, in step three, the temperature of the first compressor temperature zone is 150°C, the time is 1200s, and the pressure is 40 bar; the temperature of the second compressor temperature zone is 150°C, the time is 1300s, and the pressure is 60 bar; and the temperature of the third compressor temperature zone is 150°C, the time is 240s, and the pressure is 80 bar.

[0012] Preferably, in step three, the cooling time of the device is 2000 seconds and the pressure is 120 bar.

[0013] Compared with the prior art, the beneficial effects of the present invention are: This invention involves hot-pressing a base plate, canvas, substrate, magnetic cloth, and flooring into a hot press. The first temperature band of the press is 150°C for 1200 seconds at a pressure of 40 bar; the second temperature band is 150°C for 1300 seconds at a pressure of 60 bar; and the third temperature band is 150°C for 240 seconds at a pressure of 80 bar. The flooring is then cooled for 2000 seconds at a pressure of 120 bar, creating a magnetic padding layer. This magnetic padding layer, produced through hot-pressing and cooling, allows for easy application and installation of the suspended flooring. The installation is simple, requires no complex tools, and is fast. It also facilitates style modifications and replacements, thus improving the ease of upgrading the suspended flooring.

[0014] This invention utilizes CAD design and software programming combined with CNC engraving to refine the magnetic pad layer according to different assembly requirements. The designed magnetic pad layer is then punched into the required specifications. The punching process involves first laying the magnetic pad layer flat on a magnetic worktable, then activating the magnetic device to instantly attract the pad layer and prevent displacement. Next, the punching unit applies pressure to cut the magnetic pad layer, precisely controlling its depth and shape. Afterward, the magnetic device is deactivated, and the cut magnetic pad layer is easily removed. The precision and integrity of the cut edges are then checked to ensure the pad layer is free of burrs and deformation. This precise cutting process allows for easy disassembly and reusability of the suspended floor, enabling localized repairs of damaged sections and extending its lifespan.

[0015] This invention involves laying out magnetic pads with the magnetic side facing upwards in a staggered fashion, ensuring the magnetic side of each pad faces upwards to effectively secure the material with the adsorption device. Starting from one end of the worktable, the pads are laid layer by layer, with each layer's edges staggered by 0.5-2 cm, adjusted according to the material thickness to prevent overlap and displacement. The surface is then lightly pressed to check flatness, ensuring no wrinkles or gaps to prevent deformation during installation. Finally, suction cups are used to lay the flooring on the flattened pads, according to the irregular surface shape. This allows for individual manual operation of the suspended floor, reducing labor costs and enabling unobstructed cleaning, thus improving the convenience of suspended floor operation. Attached Figure Description

[0016] Figure 1 This is a flowchart illustrating the preparation process of the present invention; Figure 2 This is a proportional diagram of the substrate material of the drawing layer of the present invention; Figure 3 This is a data diagram showing the preparation of the substrate surface layer of the present invention; Figure 4 This is a data diagram showing the preparation process of the magnetic pad layer hot pressing process of the present invention. Detailed Implementation

[0017] 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. Example

[0018] Please see Figures 1-4 A non-circular magnetic levitation floor, comprising a base plate, canvas, substrate, magnetic cloth and floor, characterized in that: the substrate comprises polyvinyl chloride (PVC) resin, plasticizer, calcium carbonate, calcium-zinc stabilizer and carbon black.

[0019] In this embodiment: the floor is made of high-density polypropylene, the floor is toughened and modified, the surface of the floor has a quartz sand coating, the wet anti-slip coefficient is >0.7, and it has the effect of impact resistance and wear resistance, with a lifespan of 5-10 years.

[0020] The preparation method of the irregularly shaped magnetic levitation floor includes the following steps: Step 1: Pre-fabrication of the substrate: Polyvinyl chloride (PVC) resin, plasticizer, calcium carbonate, calcium-zinc stabilizer, and carbon black are fed into a high-speed mixer in proportion and stirred and mixed. The mixing temperature of the high-speed mixer is 90±15℃. 100 phr of PVC resin is added as the base material, 30-60 phr of plasticizer is added to provide flexibility and processability, 20-40 phr of calcium carbonate is added as a filler to reduce costs and increase strength, 2-4 phr of calcium-zinc stabilizer is added to ensure thermal stability, and 0.5-1.5 phr of carbon black is added for color adjustment, which can be adjusted according to decorative requirements. Step Two: Preparation of the Substrate Surface Layer: The mixed polyvinyl chloride (PVC) resin, plasticizer, calcium carbonate, calcium-zinc stabilizer, and carbon black are fed into the head roll of an open mill for preparation. The head roll temperature is 160±25℃, and the main mill speed is 50±10 rpm. Then, it is fed into the second roll of the open mill for preparation. The second roll temperature is 160±25℃, and the main mill speed is 50±10 rpm. Next, it is fed into the first sheeting roll for preparation. The first sheeting roll temperature is 180±25℃, and the main mill speed is 20±10 rpm. Finally, it is fed into the second sheeting roll for preparation. The second sheeting roll temperature is 170±25℃. At 5℃, the main machine speed is 25±10, and then it is conveyed to the three output rollers for preparation. The temperature of the three output rollers is 150±25℃, and the main machine speed is 35±15. Then it is conveyed to the four output rollers for preparation. The temperature of the four output rollers is 150±25℃. Then it is conveyed to the lead-out roller speed for preparation. The lead-out roller speed is 45±15, and the cooling roller speed is 50±15. Then it is conveyed to the cooling roller speed to form the surface substrate. This allows for multiple processes to be used to prepare the surface layer of the substrate, resulting in high quality of the surface layer during use, thereby extending the service life and wear resistance of the surface layer. Step 3: Hot Press Process Preparation: The base plate, canvas, substrate, magnetic cloth, and flooring are placed in a hot press and hot pressed. The temperature of the first press section is 150℃, the time is 1200s, and the pressure is 40bar; the temperature of the second press section is 150℃, the time is 1300s, and the pressure is 60bar; the temperature of the third press section is 150℃, the time is 240s, and the pressure is 80bar. The cooling time is 2000s, and the pressure is 120bar, creating a magnetic pad layer. This magnetic pad layer, made by hot pressing and cooling, can be easily attached and used. The installation method of the suspended floor is simple, and no complicated tools are required for installation. The installation speed of the suspended floor is fast, and it is convenient to modify and change the style of the suspended floor, thereby improving the convenience of upgrading the suspended floor. Step 4: Magnetic Pad Design: The magnetic pad is designed using CAD and software programming, and then engraved and refined using CNC. The designed magnetic pad is then punched into the required specifications. The punching process involves first laying the magnetic pad flat on a magnetic worktable, then activating the magnetic device to instantly attract the pad and prevent displacement. Next, pressure is applied using the punching unit to cut the pad, precisely controlling its depth and shape. The magnetic device is then deactivated, and the cut pad is easily removed. The precision and integrity of the cut edges are then checked to ensure there are no burrs or deformations. This fine cutting process allows for easy disassembly and reassembly of the suspended floor, enabling reuse in different scenarios and allowing for partial repair of damaged sections, thus extending the lifespan of the suspended floor. Step 5: Flooring Installation: Lay the magnetic pads flat with the magnetic side facing up, staggered in sequence. Ensure the magnetic side of each pad is facing upwards to effectively secure the material with the suction device. Starting from one end of the workbench, lay the pads layer by layer, staggering the edges of each layer by 0.5-2 cm, adjusting according to the material thickness to prevent overlap and shifting. Then, gently press the surface to check for flatness, ensuring there are no wrinkles or gaps to prevent deformation during installation. Next, use the suction cup device to install the flooring on the flattened pads according to the shape of the irregular surface layer. This allows for individual manual operation of the suspended flooring, resulting in lower labor costs and enabling unobstructed cleaning, thus improving the convenience of suspended flooring operation.

[0021] In this embodiment: in step one, the amount of polyvinyl chloride (PVC) resin is 80 to 120 parts, the amount of plasticizer is 15 to 25 parts, the amount of calcium carbonate is 250 to 320 parts, the amount of calcium-zinc stabilizer is 2 to 6 parts, and the amount of carbon black is 1 to 3 parts.

[0022] In this embodiment: the thickness of the magnetic cloth in step three is between 0.3 and 1.0 mm.

[0023] In this embodiment: in step two, the temperature of the high-speed mixer is 90±15℃, the temperature of the open mill head roll is 160±25℃, the main machine speed is 50±10, the temperature of the open mill second roll is 160±25℃, the main machine speed is 50±10, the temperature of the sheeting first roll is 180±25℃, the main machine speed is 20±10, the temperature of the sheeting second roll is 170±25℃, the main machine speed is 25±10, the temperature of the sheeting third roll is 150±25℃, the main machine speed is 35±15, and the temperature of the sheeting fourth roll is 150±25℃.

[0024] In this embodiment: in step two, the main machine speed is 45±15, the lead-out roller speed is 45±15, and the cooling roller speed is 50±15.

[0025] In this embodiment: in step three, the temperature of the first compressor temperature zone is 150°C, the time is 1200s, and the pressure is 40bar; the temperature of the second compressor temperature zone is 150°C, the time is 1300s, and the pressure is 60bar; and the temperature of the third compressor temperature zone is 150°C, the time is 240s, and the pressure is 80bar.

[0026] In this embodiment: the cooling time of the equipment in step three is 2000s, and the pressure is 120bar. Example

[0027] As shown in the figure, unlike Example 1, the irregularly shaped magnetic levitation floor in this example is manufactured using the following steps: Step 1 involves cutting the semi-cured PP and short-fiber glass fiber raw materials to obtain the first raw material and the second raw material.

[0028] Step 2: Place the magnet into the assembly fixture, then place the assembly fixture containing the magnet into the dispensing machine to dispense the magnet.

[0029] Step 3: Remove the magnet and the assembly fixture after dispensing from the dispensing machine, and cover the surface of the magnet with a cover plate.

[0030] Step 4: Place the magnet behind the cover plate and the assembly fixture into a hot press for hot pressing and fixing to obtain the assembled magnetic suction assembly, and then remove the magnetic suction assembly from the assembly fixture.

[0031] Step 5 involves hot-pressing the magnetic suction assembly, the first raw material, and the second raw material to obtain a semi-finished magnetic suction backplate.

[0032] Step 6 involves milling the semi-finished magnetic backplate to obtain the finished magnetic backplate.

[0033] In summary, compared to Example 2, Example 1 utilizes a magnetically attached pad layer made through hot-pressing and cooling for convenient application. The installation of the suspended floor is simple, requiring no complex tools and is quick. It also facilitates style modifications and replacements, improving the ease of upgrading the suspended floor. The magnetically attached pad layer can be precisely cut, allowing for easy disassembly and reassembly. This allows for repeated use in different scenarios and enables partial repair of damaged sections, extending the floor's lifespan. It prevents overlap and displacement. Afterward, the surface is lightly pressed to check flatness, ensuring no wrinkles or gaps to prevent deformation during installation. Then, suction cups are used to lay the floor on the flattened pad layer, according to the irregular surface shape. Individual manual operation is possible, reducing labor costs and allowing for unobstructed cleaning, further enhancing the ease of operation.

[0034] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0035] 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 irregularly shaped magnetic levitation floor, comprising a base plate, canvas, substrate, magnetic cloth, and flooring, characterized in that: The substrate includes polyvinyl chloride (PVC) resin, plasticizer, calcium carbonate, calcium-zinc stabilizer, and carbon black.

2. The irregularly shaped magnetic levitation floor according to claim 1, characterized in that: The floor is made of high-density polypropylene.

3. A method for preparing an irregularly shaped magnetic levitation floor, based on the irregularly shaped magnetic levitation floor according to any one of claims 1-2, characterized in that, Includes the following steps: Step 1: Pre-fabrication of substrate: Polyvinyl chloride (PVC) resin, plasticizer, calcium carbonate, calcium zinc stabilizer and carbon black are fed into a high-speed mixer in proportion and stirred and mixed. Step 2: Preparation of the substrate surface layer: The mixed polyvinyl chloride (PVC) resin, plasticizer, calcium carbonate, calcium zinc stabilizer and carbon black are fed into the first roll of the open mill for preparation, then into the second roll of the open mill for preparation, then into the first sheeting roll for preparation, then into the second sheeting roll for preparation, then into the third sheeting roll for preparation, then into the fourth sheeting roll for preparation, then into the fourth sheeting roll for preparation, then into the fourth roll for preparation, then into the fourth roll for preparation, then into the fourth roll for preparation, then into the fourth roll for preparation, then into the fourth roll for preparation, then into the fifth roll for preparation, and finally into the fourth roll for preparation, then into the fifth roll for preparation, and finally into the fifth roll for preparation to form the surface layer substrate. Step 3: Hot pressing process preparation: Place the embossed plate, canvas, PVC wear-resistant layer, face film, substrate, magnetic cloth and base pattern plate into a hot press and press them together. After cooling, the magnetic surface layer is formed. Step 4: Magnetic Surface Layer Design: The irregularly shaped magnetic surface layer is prepared through CAD design, software programming, and CNC engraving. Step 5: Preparation of magnetic padding layer: Place the base plate, canvas, substrate, magnetic cloth and base plate into a hot press and press them together. Cool to form a magnetic padding layer; cut the padding layer to the appropriate size according to the laying requirements. Step Six: Flooring Installation: Lay the magnetic pads with the magnetic side facing up in a staggered pattern. Then, install the flooring on the flat pads according to the shape of the irregular surface layer.

4. The method for preparing the irregularly shaped magnetic levitation floor according to claim 3, characterized in that: In step one, the amount of polyvinyl chloride (PVC) resin is 80 to 120 parts, the amount of plasticizer is 15 to 25 parts, the amount of calcium carbonate is 250 to 320 parts, the amount of calcium-zinc stabilizer is 2 to 6 parts, and the amount of carbon black is 1 to 3 parts.

5. The method for preparing the irregularly shaped magnetic levitation floor according to claim 3, characterized in that: The thickness of the magnetic cloth in step three is between 0.3 and 1.0 mm.

6. The method for preparing the irregularly shaped magnetic levitation floor according to claim 3, characterized in that: In step two, the temperature of the high-speed mixer is 90±15℃, the temperature of the open mill head roll is 160±25℃, the main machine speed is 50±10, the temperature of the open mill second roll is 160±25℃, the main machine speed is 50±10, the temperature of the sheeting first roll is 180±25℃, the main machine speed is 20±10, the temperature of the sheeting second roll is 170±25℃, the main machine speed is 25±10, the temperature of the sheeting third roll is 150±25℃, the main machine speed is 35±15, and the temperature of the sheeting fourth roll is 150±25℃, the main machine speed is 45±15.

7. The method for preparing the irregularly shaped magnetic levitation floor according to claim 3, characterized in that: In step two, the rotation speed of the lead-out roller is 45±15 and the rotation speed of the cooling roller is 50±15.

8. The method for preparing the irregularly shaped magnetic levitation floor according to claim 3, characterized in that: In step three, the temperature of compressor temperature zone one is 150℃, the time is 1200s, and the pressure is 40bar; the temperature of compressor temperature zone two is 150℃, the time is 1300s, and the pressure is 60bar; and the temperature of compressor temperature zone three is 150℃, the time is 240s, and the pressure is 80bar.

9. The method for preparing the irregularly shaped magnetic levitation floor according to claim 3, characterized in that: In step three, the cooling time for the equipment is 2000 seconds, and the pressure is 120 bar.

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