Polymer floor and preparation method thereof

Abstract

The invention provides a polymer floor and a preparation method thereof. The floor sequentially comprises a first outer layer, a first buffer layer, a first bonding layer, a base material layer, a second bonding layer, a second buffer layer and a second outer layer from top to bottom, wherein the base material layer is made of a first polymer, and the first polymer is selected from one or a mixture of more of PVC (polyvinyl chloride), PET (polyethylene glycol terephthalate), PETG (polyethylene glycol terephthalate) and TPU (thermoplastic polyurethane); wherein the first buffer layer and the second buffer layer are respectively and independently selected from one or more of non-woven fabrics and glass fiber mats; wherein the first bonding layer and the second bonding layer are blended membranes of grafted resin and a second polymer, and the second polymer is selected from one or a mixture of more of TPU (thermoplastic polyurethane), EAA (ethylene-acrylic acid copolymer) and PETG (polyethylene terephthalate glycol); wherein the first outer layer and the second outer layer are impregnated with glue.

Description

Technical Field

[0001] This invention relates to the field of flooring technology, and more specifically to a polymer flooring and its preparation method. Background Technology

[0002] Traditional laminate flooring consists of a wear layer, a decorative layer, a core layer, and a balancing layer. The core layer is mainly made of medium-density or high-density laminate, which has the advantages of being extremely wear-resistant and scratch-resistant, but also has problems such as high formaldehyde content, poor water resistance, easy deformation, and easy bulging.

[0003] CN 107165376 A discloses a method for manufacturing ultra-wear-resistant, scratch-resistant, and waterproof PVC flooring. The method involves using a thermoplastic film as a connecting layer to bond a wear-resistant layer, a decorative layer, a substrate, and a balancing layer, and then hot-pressing them together to form the flooring. The substrate is a PVC elastic substrate. This invention solves the problem of poor water resistance in traditional laminate flooring with a laminate substrate. However, it does not address the issues of warping, instability, and large shrinkage in laminate flooring caused by inconsistent shrinkage and expansion between the melamine-impregnated paper and the substrate.

[0004] CN 114278047 A discloses an ultra-wear-resistant PVC skin and its preparation method. Its structure mainly consists of melamine-impregnated wear-resistant paper, a PVC wear-resistant layer, a PVC color film, and a substrate. The melamine-impregnated wear-resistant paper and the PVC wear-resistant layer are bonded together by applying water-based epoxy resin adhesive and hot-pressing. This invention solves the bonding problem between the melamine-impregnated wear-resistant paper and the PVC color film, but the process is complex and costly. Summary of the Invention

[0005] In order to overcome at least one deficiency of the prior art, the present invention provides a polymer flooring and a method for preparing the same.

[0006] To achieve the above objectives, the present invention provides a polymer flooring, comprising, from top to bottom: a first outer layer, a first buffer layer, a first adhesive layer, a substrate layer, a second adhesive layer, a second buffer layer, and a second outer layer; wherein, the substrate layer is made of a first polymer, the first polymer being selected from one or more of PVC (polyvinyl chloride), PET (polyethylene terephthalate), PETG (polyethylene terephthalate-1,4-cyclohexanediol ester), and TPU (thermoplastic polyurethane); wherein, the first buffer layer and the second buffer layer are each independently selected from one or more of nonwoven fabric and fiberglass mat; wherein, the first adhesive layer and the second adhesive layer are a blend film of a resin grafted with a silane coupling agent and a second polymer, the second polymer being selected from one or more of TPU, EAA (ethylene-acrylic acid copolymer), and PETG, preferably PETG; wherein, the first outer layer and the second outer layer are impregnated with adhesive.

[0007] The silane coupling agent can be selected from any one or a combination of KH-570, KH560, and KH550. The resin includes any one or a combination of ethylene-vinyl acetate copolymer, POE, and EBA. The chemical formula of KH-570 silane coupling agent can be C... 10 H 20 O5Si.

[0008] The first and second buffer layers are each independently preferred to be made of glass fiber mat.

[0009] Fiberglass mat can be a non-woven composite material with fiberglass as the core substrate, in which fiberglass is randomly and evenly spread and solidified into sheets through chemical binders (such as acrylic emulsion and polyurethane emulsion) or mechanical interlacing.

[0010] Alternatively, the grafting rate can be 0.5%-2%, for example 1% or 1.5%.

[0011] Optionally, the first polymer and the second polymer may be made of the same or different materials. Optionally, the first buffer layer and the second buffer layer may be made of the same or different materials. Optionally, the first adhesive layer and the second adhesive layer may be made of the same or different materials.

[0012] Optionally, the thickness of the first adhesive layer ranges from 0.07mm to 0.2mm, preferably 0.1mm; the thickness of the second adhesive layer ranges from 0.07mm to 0.2mm, preferably 0.1mm; and the thickness of the substrate layer ranges from 3.5mm to 5.0mm.

[0013] Optionally, the interfaces between the first adhesive layer and the second adhesive layer and the substrate layer diffuse with each other and undergo molecular entanglement.

[0014] Optionally, the first outer layer and the second outer layer are each independently selected from one or more of the wear-resistant paper layer, the decorative layer, and the balancing layer, and the adhesive includes any one or more combinations of melamine resin and melamine-urea-formaldehyde.

[0015] Optionally, the first outer layer and the second outer layer may be the same or different. The first outer layer includes a wear-resistant paper layer impregnated with melamine resin and a decorative paper layer impregnated with melamine resin, or the first outer layer is decorative paper containing quartz sand impregnated with melamine resin. Optionally, the second outer layer includes a wear-resistant paper layer impregnated with melamine resin and a decorative paper layer impregnated with melamine resin, or the second outer layer is a balancing layer impregnated with melamine resin, or the second outer layer is a decorative paper layer containing quartz sand impregnated with melamine resin.

[0016] The present invention also provides a method for preparing any of the polymer floorings described above, comprising:

[0017] Preparation of the first or second adhesive layer: The second polymer, the resin grafted with silane coupling agent, the oleamide and the antioxidant are mixed in a weight ratio of 100:(10-20):(0.3-0.6):(0.4-1.5), and then the first or second adhesive layer is prepared by casting process. The antioxidant can be the sum of 1010 antioxidant and 178 antioxidant.

[0018] Hot pressing: The first outer layer, the first buffer layer, the first adhesive layer, the substrate layer, the second adhesive layer, the second buffer layer, and the second outer layer are laid out in sequence from top to bottom and placed in a laminator for hot pressing. The pressure is 5MPa-15MPa, the temperature is 130℃-160℃, and the time is 25 min-50 min.

[0019] Cold pressing: Place the hot-pressed product into a cold press, with a pressure of 10MPa-15MPa and a time of 30 min-40 min.

[0020] Optionally, the method for preparing the resin grafted with the silane coupling agent includes:

[0021] A resin with a melt index of 0.2 g / 10min to 10 g / 10min was selected as the raw material. The resin, silane coupling agent, and initiator were weighed and stirred evenly in a mass ratio of 100:(0.5-2):(0.5-1.5).

[0022] The twin-screw extrusion temperatures were set to 170±20℃, 190±20℃, 190±20℃, 190±20℃, and 190±20℃ respectively, and the extrusion speed was 5 m / min - 15 m / min.

[0023] The mixed material is poured into the extruder barrel, cooled with water, and pelletized to prepare a resin masterbatch for grafting silane coupling agent.

[0024] The initiator can be 2,5-dimethyl-2,5-di(tert-butylperoxy)hexyne-3, benzoyl peroxide, benzoyl peroxide, or other peroxides.

[0025] Optionally, the preparation method further includes a tempering test, which includes:

[0026] Let the cold-pressed product rest for 48 hours;

[0027] The health-promoting products are tempered at a rate of 5-10 m / min.

[0028] The surface temperature of the product after tempering is 85℃-95℃;

[0029] The cooling section uses air cooling, and the surface temperature of the board at the plate collection point is 25℃-30℃;

[0030] Allow the tempered product to rest for 48 hours.

[0031] Optionally, conditioning involves placing the cold-pressed product in a flat, stable environment (with controllable temperature and humidity) for a period of time. For example, this could be an environment of 25°C and 50% humidity.

[0032] Optionally, the preparation method also includes molding and grooving the polymer flooring.

[0033] Optionally, the basis weight of the first buffer layer is 20 g / m². 2 -50g / m 2 30 g / m 2 The weight of the second buffer layer is 20 g / m³. 2 -50g / m 2 30 g / m 2 .

[0034] In summary, the polymer flooring provided by this invention incorporates a buffer layer, which is selected from one or more materials with a highly porous internal structure, such as non-woven fabric and fiberglass mat. The first buffer layer directly contacts the first outer layer, and the second buffer layer directly contacts the second outer layer. Both the first and second outer layers are impregnated with adhesive. Therefore, the adhesive penetrates into the pores of the buffer layer during the flooring manufacturing process (e.g., under temperature and pressure), bonding the buffer layer and the outer layer together as a whole, effectively solving the problem of poor outer layer adhesion. The polymer flooring does not require additional adhesive coating; neither the first nor the second buffer layer needs to be impregnated with adhesive. The adhesive from either the first or second outer layer penetrates into the porous structure of the first and second buffer layers.

[0035] Secondly, the adhesive layer of the polymer flooring provided by this invention is placed between the buffer layer and the substrate layer, further strengthening the bond strength between the buffer layer and the polymer substrate layer, while preventing delamination of the buffer layer due to insufficient cohesion. The first or second adhesive layer also utilizes the fluidity of the polymer to penetrate into the first or second buffer layer, such as a non-woven fabric. This integrates the outer layer impregnated with adhesive, the buffer layer, the polymer adhesive layer, and the substrate layer into a single unit.

[0036] Grafted silanol groups The hydroxyl groups in the buffer layer undergo dehydration condensation to form stable Si-O-Si covalent bonds, "anchoring" the adhesive layer to the surface of the buffer layer, such as the glass fiber layer.

[0037] Moreover, due to the good toughness and ductility of the buffer layer and adhesive layer, the problems of easy cracking caused by the brittleness and large shrinkage of the melamine decorative layer are improved. Secondly, the buffer layer can also reduce the shrinkage rate of the outer layer (such as melamine impregnated paper) after curing, thereby solving the problem of warping and instability of polymer reinforced flooring.

[0038] In the method for preparing polymer flooring provided by the invention, each layer of the polymer flooring can be directly hot-pressed without the need for bonding with other adhesives. Attached Figure Description

[0039] Figure 1 This is a schematic diagram of the structure of the polymer flooring provided in Embodiment 1 of the present invention;

[0040] Figure 2 This is a schematic diagram of the polymer flooring provided in Embodiment 3 of the present invention;

[0041] Figure 3 This is a schematic diagram of the polymer flooring provided in Embodiment 4 of the present invention;

[0042] Figure 4 This is a schematic diagram of the polymer flooring provided in Embodiment 5 of the present invention;

[0043] 1-Abrasion-resistant paper layer impregnated with melamine resin; 2-Decorative paper layer impregnated with melamine resin; 3-First buffer layer and first adhesive layer; 3'-Second buffer layer and second adhesive layer; 4-Substrate layer; 5-Balancing layer impregnated with melamine resin; 6-Decorative paper layer impregnated with melamine resin containing quartz sand. Detailed Implementation

[0044] To make the above and other objects, features and advantages of the present invention more apparent and understandable, preferred embodiments are described below in detail with reference to the accompanying drawings.

[0045] Example 1 (Strong composite flooring with added fiberglass mat and grafted modified adhesive layer)

[0046] The layered structure of polymer flooring, such as Figure 1 As shown, from top to bottom, the structure includes: a melamine resin-impregnated abrasion-resistant paper layer 1, a melamine resin-impregnated decorative paper layer 2, a first buffer layer and a first adhesive layer 3, a substrate layer 4, a second adhesive layer and a second buffer layer 3', and a melamine resin-impregnated balancing layer 5. Because the first buffer layer and the first adhesive layer diffuse into each other at the interface, and the adhesive layer entangles with the substrate molecules, a strong interface is formed between the adhesive layer and the substrate. Therefore, the first buffer layer and the first adhesive layer are drawn together, and the second buffer layer and the second adhesive layer are drawn similarly.

[0047] PVC was selected as the first polymer, and the thickness of the substrate layer was 4 mm.

[0048] Both the first and second buffer layers are made of fiberglass mat. The basis weight of both the first and second buffer layers is 30 g / m². 2 .

[0049] Both the first and second adhesive layers are blend films of ethylene-vinyl acetate copolymer grafted with KH-570 silane coupling agent and a second polymer, PETG. The thickness of both the first and second adhesive layers is 0.1 mm.

[0050] The manufacturing process of this polymer flooring includes:

[0051] S1, Preparation of ethylene-vinyl acetate copolymer grafted with KH-570 silane coupling agent:

[0052] S11: Using ethylene-vinyl acetate copolymer with a melt index of 0.2 g / 10min - 10 g / 10min as raw material, weigh and stir the ethylene-vinyl acetate copolymer, KH-570 silane coupling agent, and 2,5-dimethyl-2,5-di(tert-butylperoxy)hexyne-3 at a mass ratio of 100:2:0.9.

[0053] S12: Set the twin-screw extrusion temperature to 170℃, 190℃, 190℃, 190℃, and 190℃ respectively, and the extrusion speed to 10m / min;

[0054] S13: Pour the mixed material into the extruder barrel, cool it with water, and granulate it to prepare ethylene-vinyl acetate copolymer masterbatch grafted with KH-570 silane coupling agent;

[0055] S2, Preparation of the first or second adhesive layer: The second polymer, ethylene-vinyl acetate copolymer grafted with KH-570 silane coupling agent, oleamide, and antioxidants (1010 and 178) are mixed in a weight ratio of 100:20:0.5:0.9, and then the first or second adhesive layer is prepared by casting process.

[0056] S3, Hot pressing: Lay out the first outer layer, first buffer layer, first adhesive layer, substrate layer, second adhesive layer, second buffer layer, and second outer layer in sequence from top to bottom, and put them into the laminator for hot pressing. The pressure is 5MPa-15MPa, the temperature is 130℃-160℃, and the time is 25 min-50 min.

[0057] S4, Cold Pressing: Place the hot-pressed product into a cold press at a pressure of 10MPa-15MPa for 35 minutes;

[0058] S5, Tempering Test:

[0059] Let the cold-pressed product rest for 48 hours;

[0060] The health-promoting products are tempered at a rate of 5 m / min - 10 m / min.

[0061] The surface temperature of the product after tempering is 85℃-95℃;

[0062] The cooling section uses air cooling, not water cooling, and the surface temperature of the board at the stacking point is 25℃-30℃.

[0063] Allow the tempered product to rest for 48 hours.

[0064] S6 involves molding and grooving the polymer flooring.

[0065] There is no sequential order between steps S1 and S2 above.

[0066] Example 2 (Reinforced flooring with added non-woven fabric and grafted modified adhesive layer)

[0067] The difference from Example 1 is that in Example 2, both the first buffer layer and the second first buffer layer are non-woven fabrics.

[0068] Example 3

[0069] The difference from Example 1 is that the polymer flooring has a layered structure as follows: Figure 2 As shown, from top to bottom, it includes: a wear-resistant paper layer 1 impregnated with melamine resin, a decorative paper layer 2 impregnated with melamine resin, a first buffer layer and a first adhesive layer 3, a substrate layer 4, a second adhesive layer and a second buffer layer 3', a decorative paper layer 2 impregnated with melamine resin, and a wear-resistant paper layer 1 impregnated with melamine resin.

[0070] Example 4

[0071] The difference from Example 1 is that the polymer flooring has a layered structure as follows: Figure 3 As shown, from top to bottom, it includes: a decorative paper layer 6 containing quartz sand impregnated with melamine resin, a first buffer layer and a first adhesive layer 3, a substrate layer 4, a second adhesive layer and a second buffer layer 3', and a balancing layer 5 impregnated with melamine resin.

[0072] Example 5

[0073] The difference from Example 1 is that the polymer flooring has a layered structure as follows: Figure 4 As shown, from top to bottom, it includes: a decorative paper layer 6 containing quartz sand impregnated with melamine resin, a first buffer layer and a first adhesive layer 3, a substrate layer 4, a second adhesive layer and a second buffer layer 3', and a decorative paper layer 6 containing quartz sand impregnated with melamine resin.

[0074] Example 6

[0075] The difference from Example 1 is that the thickness of the substrate layer is 3.5 mm. The basis weight of both the first and second buffer layers is 20 g / m². 2The thickness of both the first and second adhesive layers is 0.07 mm.

[0076] Example 7

[0077] The difference from Example 1 is that the thickness of the substrate layer is 5 mm. The basis weight of both the first and second buffer layers is 50 g / m². 2 The thickness of both the first and second adhesive layers is 0.2 mm.

[0078] Example 8

[0079] The difference from Example 1 is that,

[0080] PET was selected as the first polymer, and the thickness of the substrate layer was 4 mm.

[0081] Both the first and second buffer layers are made of fiberglass mat. The basis weight of both the first and second buffer layers is 30 g / m². 2 .

[0082] Both the first and second adhesive layers are blend films of ethylene-vinyl acetate copolymer grafted with KH-550 silane coupling agent and a second polymer, which is TPU. The thickness of both the first and second adhesive layers is 0.1 mm.

[0083] The manufacturing process of this polymer flooring includes:

[0084] S1, Preparation of ethylene-vinyl acetate copolymer grafted with KH-550 silane coupling agent:

[0085] S11: Using ethylene-vinyl acetate copolymer with a melt index of 0.2 g / 10min - 10 g / 10min as raw material, weigh and stir the ethylene-vinyl acetate copolymer, KH-550 silane coupling agent, and 2,5-dimethyl-2,5-di(tert-butylperoxy)hexyne-3 at a mass ratio of 100:0.5:0.5.

[0086] S12: Set the twin-screw extrusion temperatures to 150℃, 170℃, 170℃, 170℃, and 170℃ respectively, and the extrusion speed to 5m / min;

[0087] S13: Pour the mixed material into the extruder barrel, cool it with water, and granulate it to prepare ethylene-vinyl acetate copolymer masterbatch grafted with KH-550 silane coupling agent;

[0088] S2, Preparation of the first or second adhesive layer: The second polymer, ethylene-vinyl acetate copolymer grafted with KH-550 silane coupling agent, oleamide, and antioxidants (1010 and 178) are mixed in a weight ratio of 100:10:0.3:0.4, and then the first or second adhesive layer is prepared by casting process.

[0089] S3, Hot pressing: Lay out the first outer layer, first buffer layer, first adhesive layer, substrate layer, second adhesive layer, second buffer layer, and second outer layer in sequence from top to bottom, and put them into the laminator for hot pressing. The pressure is 5MPa-15MPa, the temperature is 130℃-160℃, and the time is 25 min-50 min.

[0090] S4, Cold pressing: Place the hot-pressed product into a cold press, with a pressure of 10MPa-15MPa and a time of 30 minutes;

[0091] S5, Tempering Test:

[0092] Let the cold-pressed product rest for 48 hours;

[0093] The health-promoting products are tempered at a rate of 5 m / min - 10 m / min.

[0094] The surface temperature of the product after tempering is 85℃-95℃;

[0095] The cooling section uses air cooling, not water cooling, and the surface temperature of the board at the stacking point is 25℃-30℃.

[0096] Allow the tempered product to rest for 48 hours.

[0097] S6 involves molding and grooving the polymer flooring.

[0098] There is no sequential order between steps S1 and S2 above.

[0099] Example 9

[0100] The difference from Example 1 is that,

[0101] PETG was selected as the first polymer, and the thickness of the substrate layer was 4 mm.

[0102] Both the first and second buffer layers are made of fiberglass mat. The basis weight of both the first and second buffer layers is 30 g / m². 2 .

[0103] Both the first and second adhesive layers are blend films of ethylene-vinyl acetate copolymer grafted with KH-560 silane coupling agent and a second polymer, EAA. The thickness of both the first and second adhesive layers is 0.1 mm.

[0104] The manufacturing process of this polymer flooring includes:

[0105] S1, Preparation of ethylene-vinyl acetate copolymer grafted with KH-560 silane coupling agent:

[0106] S11: Using ethylene-vinyl acetate copolymer with a melt index of 0.2 g / 10min - 10 g / 10min as raw material, weigh and stir the ethylene-vinyl acetate copolymer, KH-560 silane coupling agent, and 2,5-dimethyl-2,5-di(tert-butylperoxy)hexyne-3 at a mass ratio of 100:2:1.5.

[0107] S12: Set the twin-screw extrusion temperatures to 190℃, 210℃, 210℃, 210℃, and 210℃ respectively, and the extrusion speed to 15m / min;

[0108] S13: Pour the mixed material into the extruder barrel, cool it with water, and granulate it to prepare ethylene-vinyl acetate copolymer masterbatch grafted with KH-560 silane coupling agent;

[0109] S2, Preparation of the first or second adhesive layer: The second polymer, ethylene-vinyl acetate copolymer grafted with KH-560 silane coupling agent, oleamide, and antioxidants (1010 and 178) are mixed in a weight ratio of 100:20:0.6:1.5, and then the first or second adhesive layer is prepared by casting process.

[0110] S3, Hot pressing: Lay out the first outer layer, first buffer layer, first adhesive layer, substrate layer, second adhesive layer, second buffer layer, and second outer layer in sequence from top to bottom, and put them into the laminator for hot pressing. The pressure is 5MPa-15MPa, the temperature is 130℃-160℃, and the time is 25 min-50 min.

[0111] S4, Cold Pressing: Place the hot-pressed product into a cold press at a pressure of 10MPa-15MPa for 40 minutes;

[0112] S5, Tempering Test:

[0113] Let the cold-pressed product rest for 48 hours;

[0114] The health-promoting products are tempered at a rate of 5 m / min - 10 m / min.

[0115] The surface temperature of the product after tempering is 85℃-95℃;

[0116] The cooling section uses air cooling, not water cooling, and the surface temperature of the board at the stacking point is 25℃-30℃.

[0117] Allow the tempered product to rest for 48 hours.

[0118] S6 involves molding and grooving the polymer flooring.

[0119] There is no sequential order between steps S1 and S2 above.

[0120] Example 10

[0121] The difference from Example 1 is that the grafted material is not an ethylene-vinyl acetate copolymer, but a polyolefin elastomer (POE).

[0122] Example 11

[0123] The difference from Example 1 is that the grafted material is not ethylene-vinyl acetate copolymer, but ethylene-butyl acrylate copolymer (EBA).

[0124] The test results of Examples 3 to 11 above are similar to the test results in Example 1.

[0125] Comparative Example 1 (Reinforced flooring with added fiberglass mat and ungrafted modified adhesive layer)

[0126] The difference from Example 1 is that the first and second adhesive layers were not grafted or modified.

[0127] Comparative Example 2 (Reinforced flooring with added fiberglass mat and double-layer grafted modified adhesive layer)

[0128] The difference from Example 1 is that an adhesive layer is also provided between the first buffer layer and the first outer layer, and an adhesive layer is also provided between the second buffer layer and the second outer layer. The adhesive layers are made of the same material as the first and second adhesive layers in Example 1.

[0129] Comparative Example 3 (Reinforced flooring without added fiberglass mat and double-layer grafted modified adhesive layer)

[0130] Based on Comparative Example 2 above, the fiberglass mat layer was removed. Ultimately, it could not be boiled, had poor warpage stability, and exhibited significant shrinkage.

[0131] Comparative Example 4 (no pre-grafting, direct mixing)

[0132] The difference from Example 1 is that,

[0133] Both the first and second adhesive layers are blends of ethylene-vinyl acetate copolymer, KH-570 silane coupling agent, and a second polymer, PETG. The thickness of both the first and second adhesive layers is 0.1 mm.

[0134] The manufacturing process of this polymer flooring includes:

[0135] S1, Preparation of the first or second adhesive layer: The second polymer, ethylene-vinyl acetate copolymer, KH-570 silane coupling agent, oleamide, and antioxidants (1010 and 178) are mixed in a weight ratio of 100:0.2:19.8:0.5:0.9, and then the first or second adhesive layer is prepared by casting process;

[0136] S2, Hot pressing: Lay out the first outer layer, first buffer layer, first adhesive layer, substrate layer, second adhesive layer, second buffer layer, and second outer layer in sequence from top to bottom, and put them into a laminator for hot pressing. The pressure is 5MPa-15MPa, the temperature is 130℃-160℃, and the time is 25 min-50 min.

[0137] S3, Cold Pressing: Place the hot-pressed product into a cold press at a pressure of 10MPa-15MPa for 35 minutes;

[0138] S4, Tempering Test:

[0139] Let the cold-pressed product rest for 48 hours;

[0140] The health-promoting products are tempered at a rate of 5 m / min - 10 m / min.

[0141] The surface temperature of the product after tempering is 85℃-95℃;

[0142] The cooling section uses air cooling, not water cooling, and the surface temperature of the board at the stacking point is 25℃-30℃.

[0143] Allow the tempered product to rest for 48 hours.

[0144] S5 involves molding and grooving the polymer flooring.

[0145] There is no sequential order between steps S1 and S2 above.

[0146] Comparative Example 5

[0147] The difference from Example 1 is that only the glass fiber mat layer is omitted.

[0148] Comparative Example 6

[0149] The difference from Example 1 is that both the first and second buffer layers are impregnated with melamine resin.

[0150] Comparative Example 7

[0151] The difference from Example 1 is that the thickness of the substrate layer is 3.5 mm. The basis weight of both the first and second buffer layers is 20 g / m².2 The thickness of both the first and second adhesive layers is 0.2 mm. The final boiling test resulted in delamination.

[0152] Comparative Example 8

[0153] The difference from Example 1 is that the thickness of the substrate layer is 3.5 mm. The basis weight of both the first and second buffer layers is 20 g / m². 2 The thickness of both the first and second adhesive layers is 2mm. The final shrinkage rate is 0.25%, which is relatively high.

[0154] The test methods for the above embodiments and comparative embodiments are as follows:

[0155] Warping and Shrinkage - Refer to ISO 23999-2021 Warping Test Method: Use a feeler gauge to measure the gap between the edge of the floor and the table, and record the total thickness of the feeler gauge, which is the floor warping. Test at a temperature of (23±2)℃ and a relative humidity of (50±5)%.

[0156] Shrinkage test method: Before testing, use calipers to measure the edge length of the flooring and record it as L1; place the flooring in an oven at a constant temperature of 70℃ for 6 hours, and then remove it after it has cooled naturally in the oven. Measure the edge of the flooring again using a feeler gauge and record it as L2. Shrinkage rate = ((L1-L2) / L1)*100%

[0157] Boiling water test: An alternative to the test method that is inconvenient to use peel force to assess the fit of the product. Specific method: Heat water in a constant temperature water bath to 100℃, place the product inside, and remove the product after 2 hours. After natural cooling, observe whether the product shows any bulging or delamination. If no such phenomena are observed, the product is considered to have passed the fit test.

[0158] Abrasion resistance test - Refer to ISO 24388-2014 test method: Install the abrasion wheel containing S-42 sandpaper on the abrasion tester and test under an applied external force of 5.4±0.2N. Check the wear degree of the sample every 100 revolutions and replace the sandpaper every 200 revolutions. Record the number of revolutions until the initial wear point appears.

[0159] Scratch resistance test: A hard needle is slashed across the material surface under controlled conditions (load, speed, angle). The load is adjusted until the surface material appears white and rough. The load weight at this point is recorded, which is the scratch resistance value.

[0160] A comparison of the data from Example 1 and Comparative Example 2 shows that adding an extra adhesive layer (i.e., using a double-layer grafted modified adhesive layer) to the laminate flooring actually causes delamination problems. Therefore, this application achieves a delamination-free effect by simply setting a single adhesive layer between the substrate layer and the buffer layer. This technical solution completely breaks through the conventional understanding of those skilled in the art.

[0161] Comparative data shows that the blend film formed by the ethylene-vinyl acetate copolymer grafted with KH-570 silane coupling agent and the second polymer has a synergistic effect with the buffer layer. This synergistic effect makes the interfacial bonding performance and the performance of each function better than the sum of their individual effects, achieving a synergistic gain effect of 1+1>2.

[0162] Table 1. Test results of polymer reinforced flooring in each embodiment and comparative example.

[0163]

[0164] Table 2. Comparison of the stability of polymer flooring in different embodiments and comparative examples under different humidity conditions.

[0165]

[0166] Those skilled in the art should understand that, in the disclosure of this invention, the terms "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, the above terms should not be construed as limitations on the invention.

[0167] Although the present invention has been disclosed above by way of preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art may make some modifications and refinements without departing from the spirit and scope of the present invention. Therefore, the scope of protection of the present invention shall be determined by the scope of protection claimed in the claims.

Claims

1. A polymer flooring, characterized in that, From top to bottom, it includes: a first outer layer, a first buffer layer, a first adhesive layer, a substrate layer, a second adhesive layer, a second buffer layer, and a second outer layer; The substrate layer is made of a first polymer, which is selected from one or more of PVC, PET, PETG, and TPU. The first buffer layer and the second buffer layer are each independently selected from one or more of non-woven fabric and glass fiber mat; Wherein, the first adhesive layer and the second adhesive layer are blend films of a resin grafted with a silane coupling agent and a second polymer, wherein the second polymer is selected from one or more of TPU, EAA, and PETG. The first outer layer and the second outer layer are impregnated with glue; The silane coupling agent is selected from any one or more combinations of KH-570, KH560, and KH550; The resin includes any one or more combinations of ethylene-vinyl acetate copolymer, POE, and EBA.

2. The polymer flooring according to claim 1, characterized in that, The thickness of the first adhesive layer ranges from 0.07mm to 0.2mm, the thickness of the second adhesive layer ranges from 0.07mm to 0.2mm, and the thickness of the substrate layer ranges from 3.5mm to 5.0mm.

3. The polymer flooring according to claim 1, characterized in that, The first adhesive layer and the second adhesive layer diffuse into each other and form molecular entanglements with the substrate layer at their respective interfaces.

4. The polymer flooring according to claim 1, characterized in that, The first outer layer and the second outer layer are each independently selected from one or more of the wear-resistant paper layer, the decorative layer, and the balancing layer, and the adhesive includes any one or more combinations of melamine resin and melamine urea-formaldehyde.

5. The polymer flooring according to claim 4, characterized in that, The first outer layer and the second outer layer may be the same or different. The first outer layer includes a wear-resistant paper layer impregnated with melamine resin and a decorative paper layer impregnated with melamine resin, or the first outer layer is decorative paper containing quartz sand impregnated with melamine resin. The second outer layer includes a wear-resistant paper layer impregnated with melamine resin and a decorative paper layer impregnated with melamine resin, or the second outer layer is a balancing layer impregnated with melamine resin, or the second outer layer is a decorative paper layer containing quartz sand impregnated with melamine resin.

6. A method for preparing a polymer flooring according to any one of claims 1 to 5, characterized in that, include: Preparation of the first or second adhesive layer: The weight ratio of the second polymer, the resin grafted with silane coupling agent, the oleic acid amide, and the antioxidant is mixed at 100:(10-20):(0.3-0.6):(0.4-1.5), and then the first or second adhesive layer is prepared by casting process. Hot pressing: The first outer layer, the first buffer layer, the first adhesive layer, the substrate layer, the second adhesive layer, the second buffer layer, and the second outer layer are laid out in sequence from top to bottom and placed in a laminator for hot pressing. The pressure is 5MPa-15MPa, the temperature is 130℃-160℃, and the time is 25min-50min. Cold pressing: Place the hot-pressed product into a cold press, with a pressure of 10MPa-15MPa and a time of 30min-40min.

7. The method for preparing polymer flooring according to claim 6, characterized in that, The method for preparing the resin grafted with the silane coupling agent includes: Using ethylene-vinyl acetate copolymer with a melt index of 0.2 g / 10min - 10 g / 10min as raw material, weigh and stir the ethylene-vinyl acetate copolymer, silane coupling agent, and initiator in a mass ratio of 100:(0.5-2):(0.5-1.5) until homogeneous. The twin-screw extrusion temperatures were set to 170±20℃, 190±20℃, 190±20℃, 190±20℃, and 190±20℃ respectively, and the extrusion speed was 5m / min - 15m / min. The mixed material is poured into the extruder barrel, cooled with water, and pelletized to prepare a resin masterbatch for grafting silane coupling agent.

8. The method for preparing the polymer flooring according to claim 6, characterized in that, The preparation method further includes a tempering test, which includes: Let the cold-pressed product rest for 48 hours; The health-promoting products are tempered at a rate of 5m / min - 10m / min. The surface temperature of the product after tempering is 85℃-95℃; The cooling section uses air cooling, and the surface temperature of the board at the plate collection point is 25℃-30℃; Allow the tempered product to rest for 48 hours.

9. The method for preparing the polymer flooring according to claim 6, characterized in that, The preparation method also includes molding and grooving the polymer flooring.

10. The method for preparing the polymer flooring according to claim 6, characterized in that, The first buffer layer has a weight of 20g / m³. 2 -50g / m 2 The weight of the second buffer layer is 20 g / m³. 2 -50g / m 2 .

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