Multi-dimensional fiber mesh reinforced lightweight high-strength SPC flooring and its continuous molding process
By hot-pressing the multi-dimensional fiber mesh reinforcement layer and the SPC substrate layer together, the locking parts are precisely reinforced, solving the problem of easy damage to the SPC floor locking system. This achieves high-strength and low-cost locking part reinforcement, suitable for various scenarios and compatible with existing production lines.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- 季资元
- Filing Date
- 2026-04-17
- Publication Date
- 2026-06-02
AI Technical Summary
Existing SPC flooring is prone to problems such as cracking of the female groove and breakage of the male groove at the locking point, and the bonding between the reinforcement layer and the substrate is poor, resulting in a decrease in the stability of the flooring. The existing reinforcement method is difficult to balance strength and cost.
It adopts a multi-dimensional fiber mesh reinforcement layer, including single, double or multiple fiber reinforcement layers, which are distributed along the length, width or cross mesh of the floor. It is hot-pressed and integrated with the SPC substrate layer to precisely reinforce the key stress area of the locking system. It adopts a continuous molding process and is compatible with existing production lines.
It significantly improves the shear and fracture resistance of the locking parts, reduces cracking and breakage rates, ensures the overall structural stability of the flooring, has a wide range of applications, is cost-controllable, and can be adapted to existing production lines without large-scale modifications.
Abstract
Description
Technical Field
[0001] This invention relates to the field of building decoration materials technology, specifically to multi-dimensional fiber mesh reinforced lightweight high-strength SPC flooring and its continuous molding process, which is particularly suitable for floor decoration scenarios such as homes, commercial spaces, and industrial plants where high mechanical properties and service life are required. Background Technology
[0002] SPC (Stone Plastic Composite) flooring is a new type of decorative flooring made from polyvinyl chloride resin as the base material and fillers such as heavy calcium carbonate through processes such as extrusion, calendering, and shaping. It is widely used in the field of building decoration due to its advantages such as good dimensional stability, waterproof and moisture-proof, wear-resistant and easy to clean, and convenient installation.
[0003] However, existing SPC flooring still has significant technical defects in actual use. In particular, the locking mechanism is a weak point in the core structure. The upper wall of the female groove, the root of the male groove, and the lower wall of the female groove are the three key stress points. Under stress from splicing, repeated disassembly and assembly, or long-term use, problems such as cracking of the female groove, breakage of the male groove, and chipping of the locking mechanism are very likely to occur, resulting in larger gaps between the flooring and reduced stability. The current industry reinforcement methods are mostly formula adjustments or local thickening. Formula adjustments can only slightly improve toughness, while local thickening increases raw material costs and floor weight, and it is difficult to achieve targeted reinforcement of the key stress areas of the locking mechanism. At the same time, some reinforced SPC flooring has the problem of poor bonding between the reinforcement layer and the substrate, and is prone to delamination, which further reduces the overall performance.
[0004] In summary, the industry urgently needs a structural reinforcement design and a matching continuous molding process for the key stress areas of SPC flooring locking systems. This process should be able to achieve precise reinforcement of the locking parts without significantly increasing the thickness and cost of the boards, and should be compatible with existing production lines, facilitating industrialization. Summary of the Invention
[0005] The purpose of this invention is to overcome the technical defects of existing SPC flooring and provide a multi-dimensional fiber mesh reinforced lightweight high-strength SPC flooring and its continuous molding process. By precisely deploying fiber reinforcement layers in the key stress areas of the locking mechanism, targeted reinforcement of the locking parts is achieved, improving the overall mechanical properties of the flooring, while ensuring the compatibility and economy of the manufacturing process, thus solving the problem of difficulty in balancing strength and cost in the existing technology.
[0006] To achieve the above objectives, the present invention adopts the following technical solution:
[0007] A multi-dimensional fiber mesh reinforced lightweight high-strength SPC flooring includes an SPC substrate layer and fiber reinforcement layers. The fiber reinforcement layers are single-layer, double-layer, or multi-layer stacked structures. The multiple fiber reinforcement layers are distributed along the length and width of the flooring or in a cross-mesh pattern. Each fiber reinforcement layer is embedded inside the SPC substrate layer, and the fiber reinforcement layer and the SPC substrate layer are thermo-pressed into a single structure with a bonding strength ≥3MPa.
[0008] Furthermore, taking a three-layer fiber reinforcement layer as an example, the first fiber reinforcement layer is disposed in the SPC substrate layer near the upper surface of the floor to enhance the strength of the upper wall of the female groove; the second fiber reinforcement layer is disposed in the SPC substrate layer at the root of the corresponding male groove of the floor to enhance the fracture resistance of the male groove; and the third fiber reinforcement layer is disposed in the SPC substrate layer near the lower surface of the floor to enhance the strength of the lower wall of the female groove.
[0009] Furthermore, the fiber reinforcement layer is one or more of a mesh structure, a fabric structure, or a randomly oriented fiber structure composed of continuous fibers, and the fiber material is selected from one or more of glass fiber, basalt fiber, polyester fiber, and aramid fiber.
[0010] Furthermore, the thickness of the SPC substrate layer is 3~10mm, the thickness of the single fiber reinforcement layer is 0.1~0.5mm, and the areal density of the single fiber reinforcement layer is 10~100g / ㎡.
[0011] Furthermore, the fiber reinforcement layer extends continuously in the floor locking area, and the fibers in the locking area and the fibers in the floor body form an integrated continuous structure.
[0012] Furthermore, the fiber reinforcement layer is locally densified in the floor locking area, or a combination of continuous extension and local densification is used in the locking area.
[0013] This invention also provides a continuous molding process for multi-dimensional fiber mesh reinforced lightweight high-strength SPC flooring, comprising the following steps:
[0014] 1) SPC substrate mixing and extrusion: After the SPC substrate raw materials are mixed evenly, they are melt-extruded to obtain a molten SPC substrate material blank;
[0015] 2) Introduction of fiber reinforcement layer: During the extrusion or calendering process of SPC base material blank, single-layer, double-layer or multi-layer fiber reinforcement layer is accurately conveyed to the preset position through independent unwinding and positioning devices, and initially compounded with the molten SPC base material;
[0016] 3) Hot pressing and cooling: The preliminarily composite blanks are hot pressed together and then cooled and shaped to obtain a composite board blank;
[0017] 4) Locking and surface treatment: The locking structure is processed on the composite board blank and the surface is sanded to obtain the finished product.
[0018] Furthermore, in step 1), the melt extrusion temperature is 150~180℃, and the screw speed of the twin-screw extruder is 300~500r / min.
[0019] Furthermore, in step 2), the conveying speed of each fiber reinforcement layer is synchronized with the extrusion or calendering speed of the SPC base material blank, with a synchronization error ≤ ±0.5m / min.
[0020] Furthermore, in step 3), the hot pressing temperature is 140~170℃, the hot pressure is 10~30MPa, the holding time is 1~5min, and the cooling and shaping temperature is 25~40℃.
[0021] In step 4), the locking mechanism is machined using CNC diamond tools for mechanical grooving. During the machining process, air cooling is used to keep the temperature of the machining area below 60°C and to ensure the continuity of the fiber reinforcement layer in the locking area.
[0022] Compared with the prior art, the present invention has the following beneficial effects:
[0023] The fiber reinforcement layer can be flexibly laid out in single, double or multiple layers. Multiple layers can be distributed along the length, width or in a cross mesh pattern to precisely match the key weak areas of the SPC flooring locking system, achieving targeted functional reinforcement of the locking parts, significantly improving the shear and fracture resistance of the locking parts, significantly reducing the incidence of cracking of the female groove, breakage of the male groove, and chipping of the locking edge, and improving the stability and service life of the flooring splicing;
[0024] The fiber reinforcement layer and the SPC substrate layer are integrated by hot pressing, with a bonding strength of ≥3MPa. There is no delamination or peeling, which meets the mechanical performance requirements of SPC high hardness composite materials. This ensures the overall structural stability of the floor and effectively avoids problems such as reinforcement layer peeling and substrate cracking during use.
[0025] The thickness of a single fiber reinforcement layer is only 0.1~0.5mm, and the areal density is extended to 10~100g / ㎡. This not only meets the need for dense reinforcement in the locking area, but also does not significantly increase the overall thickness and weight of the SPC composite flooring. The cost of fiber materials is controllable, balancing performance improvement and cost control.
[0026] The fiber material and structural form of the fiber reinforcement layer can be flexibly selected according to the application scenario. It is suitable for industrial plants, computer rooms and other scenarios that require weather resistance and high strength, as well as home furnishings, commercial showrooms and other scenarios that require lightweight and decorative features. It can also be adapted to humid scenarios such as bathrooms and balconies, with a wide range of applications.
[0027] The continuous molding process follows the physical logic of actual SPC flooring production. The extrusion temperature is higher than the hot pressing temperature to avoid secondary melting and deformation of the substrate. The locking process adopts a mature CNC diamond tool mechanical grooving process, which is compatible with industrial board speeds of 5~15m / min. It is highly compatible with existing SPC flooring production lines. Only the unwinding and positioning devices for the fiber reinforcement layer need to be added. There is no need for large-scale modification of existing production equipment. The modification cost is low, and industrial continuous production can be directly realized with high production efficiency.
[0028] This invention protects the core concept of precise layering in the key stress area of the locking mechanism. It is not limited to the number of fiber layers. Any reference to or application of this concept falls within the scope of protection. The scope of protection is broad and can effectively protect the core technology of the invention. Detailed Implementation
[0029] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to specific embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.
[0030] Example 1
[0031] A multi-dimensional fiber mesh reinforced lightweight high-strength SPC flooring has a 5mm thick SPC substrate layer. It employs three fiber reinforcement layers: the first layer is a glass fiber mesh structure, located 0.8mm from the top surface of the floor, with a thickness of 0.2mm and a surface density of 35g / m²; the second layer is a basalt fiber fabric structure, located at the center of the groove root, with a thickness of 0.2mm and a surface density of 35g / m²; and the third layer is a glass fiber mesh structure, located 0.8mm from the bottom surface of the floor, with a thickness of 0.2mm and a surface density of 35g / m². All three fiber reinforcement layers are continuously extended in the locking area, seamlessly connecting with the flooring fibers. Furthermore, each fiber reinforcement layer and the SPC substrate layer are hot-pressed at 160℃ and 20MPa to form an integrated structure with a bonding strength of 3.5MPa.
[0032] The continuous molding process includes: SPC base material is mixed according to the formula and then melt-extruded at 160℃ using a twin-screw extruder with a screw speed of 400r / min; during the calendering stage, the three fiber reinforcement layers are precisely conveyed to the preset positions by three sets of independent unwinding devices, with the conveying speed synchronized with the calendering speed and an error of ±0.3m / min; after hot pressing and holding at 160℃ and 20MPa for 2 minutes, it is cooled and shaped at 30℃; the locking structure is machined by mechanical grooving using CNC diamond tools, the tool speed is optimized to reduce fiber damage, and the processing is air-cooled to below 50℃ to ensure fiber continuity in the locking area; finally, the surface is sanded to obtain the finished flooring.
[0033] Example 2
[0034] A multi-dimensional fiber mesh reinforced lightweight high-strength SPC flooring has an SPC substrate layer thickness of 6mm. It employs a double-layer fiber reinforcement structure with two layers arranged in a cross-mesh pattern. The first fiber reinforcement layer is a polyester fiber mesh structure with a thickness of 0.15mm and an areal density of 40g / ㎡. The second fiber reinforcement layer is an aramid fiber randomly oriented structure with a thickness of 0.2mm and an areal density of 40g / ㎡. Both fiber reinforcement layers undergo localized densification treatment in the locking area, with the areal density of the densified area being twice that of the undensified area. Each fiber reinforcement layer and the SPC substrate layer are hot-pressed at 165℃ and 25MPa to form an integrated structure with a bonding strength of 4.0MPa.
[0035] Its continuous molding process includes: SPC base material is mixed and then melt-extruded at 170℃ using a twin-screw extruder with a screw speed of 450r / min; during the extrusion process, the double-layer fiber reinforcement layer is precisely conveyed to the preset position through two sets of independent unwinding devices, with the conveying speed synchronized with the extrusion speed and an error of ±0.2m / min; after hot pressing and holding at 165℃ and 25MPa for 3 minutes, it is cooled and shaped at 35℃; the locking structure is machined by mechanical grooving using CNC diamond tools, and the processing is air-cooled to below 45℃; finally, the surface is sanded to obtain the finished flooring.
[0036] Example 3
[0037] A multi-dimensional fiber mesh reinforced lightweight high-strength SPC flooring has a 4mm thick SPC substrate layer. It employs three fiber reinforcement layers: the first layer is a glass fiber + aramid fiber hybrid mesh structure, located 0.6mm from the top surface of the floor, with a thickness of 0.1mm and a surface density of 25g / ㎡; the second layer is a basalt fiber + polyester fiber hybrid woven structure, located at the root of the grooves, with a thickness of 0.15mm and a surface density of 30g / ㎡; the third layer is a glass fiber + aramid fiber hybrid mesh structure, located 0.6mm from the bottom surface of the floor, with a thickness of 0.1mm and a surface density of 25g / ㎡. The three fiber reinforcement layers are continuously extended and locally densified in the locking area, with the density of the densified area being 2.5 times that of the undensified area. Each fiber reinforcement layer and the SPC substrate layer are hot-pressed at 155℃ and 15MPa to form an integrated structure with a bonding strength of 3.2MPa.
[0038] The continuous molding process includes: SPC substrate raw materials are mixed and then melt-extruded at 155℃ using a twin-screw extruder with a screw speed of 350r / min; at the extrusion die, three fiber reinforcement layers are precisely conveyed to the preset position through three sets of independent unwinding devices, with the conveying speed synchronized with the extrusion speed and an error of ±0.4m / min; after hot pressing and holding at 155℃ and 15MPa for 1.5min, the material is cooled and shaped at 28℃; the locking structure is machined by mechanical grooving using CNC diamond tools, optimizing the tool angle to reduce fiber damage, and the processing is air-cooled to below 55℃; finally, the surface is sanded to obtain the finished flooring.
[0039] The multi-dimensional fiber mesh reinforced lightweight high-strength SPC flooring prepared in the above embodiments, after testing, showed that the shear strength of the locking part was increased by 45% to 65% compared with ordinary SPC flooring, the incidence of cracking of the female groove and breakage of the male groove was reduced by more than 85%, and there was no delamination or peeling between the fiber reinforcement layer and the SPC substrate layer. It can be directly adapted to existing SPC flooring production lines for industrial production.
[0040] The scope of protection of this invention is defined by the claims. This specification and specific embodiments are only used to explain this invention. The core of this invention is the fiber-reinforced structure design concept of precise layering in the key stress area of the locking mechanism. It is not limited to the number of fiber reinforcement layers. Any SPC floor fiber reinforcement structure design that draws on this core concept falls within the scope of protection of this patent.
Claims
1. A multi-dimensional fiber mesh reinforced lightweight high-strength SPC flooring, comprising an SPC substrate layer and a fiber reinforcement layer, characterized in that, The fiber reinforcement layer is a single-layer, double-layer, or multi-layer stacked structure. The multiple fiber reinforcement layers are distributed along the length and width of the floor or in a cross-network pattern. Each fiber reinforcement layer is embedded inside the SPC substrate layer, and the fiber reinforcement layer and the SPC substrate layer are a thermo-pressed integrated structure with a bonding strength ≥3MPa.
2. The multi-dimensional fiber mesh reinforced lightweight high-strength SPC flooring according to claim 1, characterized in that, Taking a three-layer fiber reinforcement layer as an example, the first fiber reinforcement layer is set in the SPC substrate layer near the upper surface of the floor to enhance the strength of the upper wall of the female groove; the second fiber reinforcement layer is set in the SPC substrate layer at the root of the corresponding male groove of the floor to enhance the fracture resistance of the male groove; and the third fiber reinforcement layer is set in the SPC substrate layer near the lower surface of the floor to enhance the strength of the lower wall of the female groove.
3. The multi-dimensional fiber mesh reinforced lightweight high-strength SPC flooring according to claim 1, characterized in that, The fiber reinforcement layer is one or more of a mesh structure, a fabric structure, or a randomly oriented fiber structure made of continuous fibers, and the fiber material is selected from one or more of glass fiber, basalt fiber, polyester fiber, and aramid fiber.
4. The multi-dimensional fiber mesh reinforced lightweight high-strength SPC flooring according to claim 1, characterized in that, The thickness of the SPC substrate layer is 3~10mm, the thickness of the single fiber reinforcement layer is 0.1~0.5mm, and the areal density of the single fiber reinforcement layer is 10~100g / ㎡.
5. The multi-dimensional fiber mesh reinforced lightweight high-strength SPC flooring according to claim 1, characterized in that, The fiber reinforcement layer extends continuously in the floor locking area, and the fibers in the locking area and the fibers in the floor body form an integrated continuous structure.
6. The multi-dimensional fiber mesh reinforced lightweight high-strength SPC flooring according to claim 1, characterized in that, The fiber reinforcement layer is locally densified in the floor locking area, or a combination of continuous extension and local densification is used in the locking area.
7. Claims The continuous molding process of any one of the multi-dimensional fiber mesh reinforced lightweight high-strength SPC flooring is characterized in that, Includes the following steps: 1) SPC substrate compounding and extrusion: After the SPC substrate raw materials are mixed evenly, they are melt-extruded to obtain a molten SPC substrate material blank; 2) Introduction of fiber reinforcement layer: During the extrusion or calendering process of SPC base material blank, single-layer, double-layer or multi-layer fiber reinforcement layer is accurately conveyed to the preset position through independent unwinding and positioning devices, and initially compounded with the molten SPC base material; 3) Hot pressing and cooling: The preliminarily composite blanks are hot pressed together and then cooled and shaped to obtain a composite board blank; 4) Locking and surface treatment: The locking structure is processed on the composite board blank and the surface is sanded to obtain the finished product.
8. The continuous molding process according to claim 7, characterized in that, In step 1), the melt extrusion temperature is 150~180℃, and the screw speed of the twin-screw extruder is 300~500r / min.
9. The continuous molding process according to claim 7, characterized in that, In step 2), the conveying speed of each fiber reinforcement layer is synchronized with the extrusion or calendering speed of the SPC base material blank, with a synchronization error of ≤ ±0.5m / min.
10. The continuous molding process according to claim 7, characterized in that, In step 3), the hot pressing temperature is 140~170℃, the hot pressure is 10~30MPa, the holding time is 1~5min, and the cooling and shaping temperature is 25~40℃. In step 4), the locking mechanism is machined using CNC diamond tools for mechanical grooving. During the machining process, air cooling is used to keep the temperature of the machining area below 60°C and to ensure the continuity of the fiber reinforcement layer in the locking area.