Locking floor and method for forming same

Abstract

The present application provides a locking floor and a forming method thereof, the locking floor comprising the following structure layers: a base material layer, a locking is formed in the base material layer; a color film layer above the base material layer; a wear-resistant layer above the color film layer; and a UV layer above the wear-resistant layer, each structure layer integrally forms a main body extending in a horizontal direction and a corner portion formed at a corner of the main body and bent downwardly to transition a chamfer, wherein the wear-resistant layer at the corner portion of the locking floor has a uniform thickness measured in a vertical direction. According to the locking floor of the present application, the consistency of the corner portion or even the whole locking floor is high, so that a good appearance can be presented, and the high quality and high stability of the locking floor can be ensured.

Description

Technical Field

[0001] This invention relates to the field of click-lock flooring, and more specifically to a click-lock flooring and a method for forming and processing the click-lock flooring. Background Technology

[0002] Click-lock flooring is widely used in home furnishings and decorative materials. However, the wear and tear of the right-angled edges of click-lock flooring has always been a difficult problem to solve in flooring production. When these right-angled edges are subjected to external friction, they are more prone to stress concentration, leading to wear or damage, which in turn affects the lifespan of the flooring, as well as its flatness and installation appearance.

[0003] In traditional flooring click-lock systems, several processing methods are used for edge and corner finishing. One common method is to directly use a milling cutter to cut bevels into the small boards, but this damages the flooring surface, requiring subsequent beveling and painting to compensate, which increases production steps and operating costs. Another method involves hot-pressing the large boards along the corners before cutting them into smaller boards, creating rounded edges. After hot-pressing, a UV treatment is applied, followed by precise positioning and sawing of the large boards into smaller boards, which then require precise positioning for the click-locking process. However, this requires extremely precise board positioning, and the sawing and grooving steps can easily damage the roundness of the edges, leading to processing deviations that affect the click-locking quality and splicing stability. Furthermore, this hot-pressing method causes stress concentration at the rounded areas, which, after long-term use, will release stress and cause the rounded dimensions to spring back. Additionally, this process, involving molding on the large board before the UV treatment, can easily lead to UV paint buildup in the molding grooves, i.e., the rounded areas of the flooring, affecting the product's appearance. Therefore, traditional methods have never been able to perfectly solve the problem of corner processing.

[0004] In summary, there are many problems with the edges and corners of click-lock flooring, affecting its aesthetics and performance. Summary of the Invention

[0005] To address the above problems, according to a first aspect of the present invention, a click-lock flooring is provided, comprising the following structural layers: a substrate layer, wherein a click is formed on the substrate layer; a color film layer above the substrate layer; an abrasion-resistant layer above the color film layer; and a UV layer above the abrasion-resistant layer. Each structural layer integrally forms a main body extending in a horizontal direction and corner portions formed at the corners of the main body and curved downwards with chamfered transitions. The abrasion-resistant layer at the corner portions of the click-lock flooring has a uniform thickness measured in the vertical direction.

[0006] The locking floor according to the present invention may have one or more of the following features.

[0007] According to one embodiment, the locking floor further includes an LVT layer between the substrate layer and the color film layer, wherein the LVT layer at the corners of the locking floor has a uniform thickness measured in the vertical direction.

[0008] According to one embodiment, the relative range of the thickness of the wear-resistant layer at the corners of the locking floor, measured in the vertical direction, does not exceed 20%.

[0009] The relative range of the thickness of the LVT layer at the corners of the locking floor, measured in the vertical direction, does not exceed 20%.

[0010] According to one embodiment, with the horizontal direction as the x-axis and the vertical direction as the y-axis, the upper surface contours of the wear-resistant layer, the upper surface contours of the color filter layer, and the upper surface contours of the substrate layer at the corners respectively conform to a polynomial function.

[0011] According to one embodiment, with the horizontal direction as the x-axis and the vertical direction as the y-axis, the upper surface contours of the wear-resistant layer, the upper surface contours of the color filter layer, and the upper surface contours of the substrate layer at the corners respectively conform to a cubic polynomial function.

[0012] According to one embodiment, the coefficient of determination of the cubic polynomial function fitted to the upper surface profile of the wear-resistant layer, the upper surface profile of the color filter layer, and the upper surface profile of the substrate layer at the corners is greater than 0.95.

[0013] According to one embodiment, the structural layers at the corners of the locking floor are formed by extrusion deformation.

[0014] According to one embodiment, each structural layer at the corner of the locking floor is formed by extrusion deformation using a pressure roller, the outer contour of which is circular.

[0015] According to one embodiment, each structural layer at the corner of the locking floor is formed by being deformed by using a pressure roller and then springing back.

[0016] According to one embodiment, the corner portion is heated and softened before being extruded and deformed.

[0017] According to one embodiment, the corner portion is cut vertically after being extruded and deformed to form the final shape.

[0018] According to a second aspect of the present invention, a method for forming a click-lock floor is provided, comprising the following steps:

[0019] Forming each structural layer;

[0020] Heating softens the edges and corners of the floor;

[0021] The corners and edges are formed integrally by extrusion deformation, including downward bending and chamfering transitions of each structural layer; and

[0022] Cut the corners vertically to form the final shape of the corners.

[0023] According to one embodiment, the forming process of the click-lock flooring may further include performing the clicking process after cutting off the corners.

[0024] According to the locking floor of the present invention, the structural layers of the main body and the corners are integrally formed without any gaps. Moreover, the wear-resistant layer at the corners of the locking floor has a uniform thickness measured in the vertical direction, and does not become thinner as the corners move further outward. This results in high consistency at the corners and even the entire locking floor, whether viewed from the extension direction of the corners or from the vertical direction, thereby presenting a good appearance and ensuring the high quality and high stability of the locking floor.

[0025] Furthermore, in the locking flooring according to the present invention, the upper surface contours of the wear-resistant layer, the upper surface contours of the color film layer, and the upper surface contours of the substrate layer at the corners respectively conform to a polynomial function or a cubic polynomial function, and have a smoother, more beautiful, and more delicate splicing appearance compared with other surface contours (especially compared with pure arc-shaped surface contours). Attached Figure Description

[0026] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings of the embodiments of the present invention will be briefly described below. The drawings are merely illustrative of some embodiments of the present invention and are not intended to limit the scope of the present invention to all embodiments.

[0027] Figure 1 This is a schematic diagram of the assembly of the interlocking floor according to the present invention.

[0028] Figure 2 This is a schematic diagram illustrating the process of forming a locking floor according to the present invention.

[0029] Figure 3 This is a schematic diagram of the interlocking floorboards according to the present invention after being cut.

[0030] Figure 4 This refers to the variation in the wear layer thickness of the SPC floor according to Example 1 of the present invention.

[0031] Figure 5 This refers to the variation in the wear layer thickness of the SPC floor according to Example 2 of the present invention.

[0032] Figure 6 This refers to the variation in the wear layer thickness of the WPC flooring according to Example 3 of the present invention.

[0033] Figure 7This refers to the variation in the wear layer thickness of the WPC floor according to Example 4 of the present invention.

[0034] Figure 8 This refers to the variation in the LVT layer thickness of the WPC floor according to Example 3 of the present invention.

[0035] Figure 9 This refers to the variation in the LVT layer thickness of the WPC floor according to Example 4 of the present invention.

[0036] Figure 10 This is a contour fitting diagram of each layer of the SPC floor according to Example 1 of the present invention.

[0037] Figure 11 This is a contour fitting diagram of each layer of the SPC floor according to Example 2 of the present invention.

[0038] Figure 12 This is a contour fitting diagram of each layer of the WPC floor according to Example 3 of the present invention.

[0039] Figure 13 This is a contour fitting diagram of each layer of the WPC floor according to Example 4 of the present invention.

[0040] List of reference numerals

[0041] 10 Substrate layer

[0042] 20 color filter layers

[0043] 30 wear-resistant layer

[0044] 40 UV layers

[0045] 50 main bodies

[0046] 60 Corner Detailed Implementation

[0047] To make the objectives, technical solutions, and advantages of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. The same reference numerals in the drawings represent the same components. It should be noted that the described embodiments are only some, not all, of the embodiments of the present invention. All other embodiments obtained by those skilled in the art based on the described embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0048] Unless otherwise defined, the technical or scientific terms used herein shall have the ordinary meaning as understood by one of ordinary skill in the art to which this invention pertains. The terms “first,” “second,” and similar terms used in this patent application specification and claims do not indicate any order, quantity, or importance, but are merely used to distinguish different components. Terms such as “comprising” or “including” mean that the element or object preceding the word encompasses the element or object listed following the word and its equivalents, without excluding other elements or objects. Terms such as “connected” or “linked” are not limited to physical or mechanical connections, but can include electrical connections, whether direct or indirect. Terms such as “upper,” “lower,” “left,” and “right” are used only to indicate relative positional relationships; these relative positional relationships may change accordingly when the absolute position of the described object changes.

[0049] The present invention will be described in detail below by way of example embodiments.

[0050] This invention addresses two types of click-lock flooring: stone-plastic composite flooring (SPC) and wood-plastic composite flooring (WPC). The following description uses SPC flooring as an example and further explains the differences between WPC and SPC flooring.

[0051] refer to Figure 1 (a) and (b) are schematic diagrams, respectively, showing the assembly process and the end of assembly of two click-lock floorboards according to the present invention. It can be understood that the click-lock floorboards according to the present invention have locking parts, through which two adjacent click-lock floorboards can be assembled and fixed together. Each click-lock floorboard (e.g., SPC flooring) includes multiple structural layers, see reference... Figure 1 Specifically, it includes a bottom substrate layer 10 with a locking mechanism formed thereon; a color film layer 20 above the substrate layer 10; a wear-resistant layer 30 above the color film layer 20; and a UV layer 40 above the wear-resistant layer 30. The UV layer 40 is a transparent protective film on the outermost surface of the flooring, a hard film that is instantly cured by ultraviolet (UV) radiation. Compared to SPC flooring, WPC flooring also includes an LVT layer between the substrate layer 10 and the color film layer 20. The LVT layer, for example, is a vinyl layer that provides structural strength, thickness, and stability.

[0052] As an example, the total thickness of the SPC flooring / wall panel is 5mm~12mm. The thickness of each structural layer is as follows: UV layer 40 is 10~20um thick; wear-resistant layer 30 is 0.1~1mm thick; color film layer 20 is 0.05~0.1mm thick; and substrate layer 10 is 4~11mm thick. Therefore, apart from the substrate layer 10, among the additional layers covering the substrate layer 10, namely the color film layer 20, wear-resistant layer 30, and UV layer 40, the wear-resistant layer 30 has the largest thickness and the highest thickness proportion. The thickness variation of the wear-resistant layer 30 to some extent represents the thickness variation of the additional layers.

[0053] Similarly, the total thickness of WPC flooring / wall panels ranges from 5mm to 18mm. The thicknesses of each structural layer are as follows: UV layer 40: 10-20µm; abrasion layer 30: 0.1-1mm; color film layer 20: 0.05-0.1mm; LVT layer: 0.5-2.0mm; and substrate layer 10: 4-15mm. Therefore, apart from the substrate layer 10, among the additional layers covering the substrate layer 10—namely, the LVT layer, color film layer 20, abrasion layer 30, and UV layer 40—the LVT layer has the largest thickness and the highest proportion of thickness, followed by the abrasion layer 30. The variation in the thickness of the LVT layer, and similarly, the variation in the thickness of the abrasion layer 30, also represents the variation in the thickness of the additional layers.

[0054] According to the present invention, each structural layer integrally forms a main body 50 extending horizontally and corner portions 60 formed at the corners of the main body 50 and curved downwards with chamfered transitions. For example... Figure 1 As shown in the cross-sectional view of the click-lock flooring, the center of each click-lock flooring is the main body 50, and the portions on both sides of the main body 50 that are adjacent to the adjacent click-lock flooring are the corner portions 60. According to the invention, the wear-resistant layer 30 at the corner portions 60 of the click-lock flooring has a uniform thickness measured in the vertical direction. Here, the uniform thickness of the wear-resistant layer 30 at the corner portions 60 means that the wear-resistant layer 30 is sampled and calculated substantially throughout the entire corner portion 60. The inventors of the present invention have discovered through research and experimentation that when the structural layers of the main body 50 and the corner portions 60 of the click-lock flooring are integrally formed, the corner portions 60 are bent downwards with chamfered transitions, and the wear-resistant layer 30 at the corner portions 60 has a uniform thickness measured in the vertical direction, the click-lock flooring can exhibit a good appearance and ensure high quality and high stability.

[0055] The integral formation of the structural layers of the main body 50 and the corner portion 60 here means that, for each structural layer (e.g., wear-resistant layer 30), the structural layers at the main body 50 and the corner portion 60 are formed together, with no abrupt change at the transition between the main body 50 and the corner portion 60, and the structural layers are formed in the direction of extension of the structural layers (e.g., in...). Figure 1In the main body 50, the general left-right direction and the downward bending direction of the corner portion 60 are continuous and uninterrupted. To ensure the integral formation of each structural layer of the main body 50 and the corner portion 60, the structural layers at the corner portion 60 of the locking floor according to the present invention are integrally formed by extrusion deformation. Specifically, as an embodiment, the corner portion 60 of the locking floor undergoes heating and softening, extrusion deformation using pressure rollers, springback, and is cut vertically to form the final shape. The outer contour of the pressure rollers is circular, and the corner portion 60 of the locking floor undergoes extrusion by multiple pressure rollers. That is, the forming process of the locking floor according to the present invention includes the steps of: forming each structural layer (such as...) Figure 2 (a) shows); heating softens the corners of the floor; forming a corner portion 60 by extrusion deformation, including the downward bending chamfer transition of each structural layer (as shown in (a)). Figure 2 (b) shown); and trimming the corners 60 vertically to form the final shape; performing the locking process (as shown in the diagram). Figure 2 As shown in (c), the result is that the color film layer 20, wear-resistant layer 30, and UV layer 40 are formed by planar deformation, rather than by coating, plating, or other methods after forming. Therefore, it has the following advantages: 1) Mechanical performance: The formed arc surface retains the complete UV layer 40, wear-resistant layer 30, and patterned paper layer, making the easily worn edges more wear-resistant. Since the arc chamfer is formed by removing part of the material and then heating and extruding, stress concentration will not occur at the arc position, so the arc position will not spring back and the dimensions are more stable after long-term use. 2) Aesthetics: The arc edges are more aesthetically pleasing than the beveled chamfer, retaining the color film layer 20, and the overall appearance of the floor is better. This process of first applying UV and then molding, compared with the traditional process of first molding a large board and then applying UV treatment, will not form UV paint accumulation at the arc edge, thus making the arc more aesthetically pleasing.

[0056] The wear-resistant layer 30 at the corner 60 has a uniform thickness measured in the vertical direction. Compared with the wear-resistant layer 30 becoming thinner as it moves further outward from the corner 60, the uniform thickness ensures high consistency of the corner 60 and even the entire click-lock floor, whether from the extension direction of the corner 60 or from the vertical direction. This results in a good appearance and ensures the high quality and high stability of the click-lock floor.

[0057] Specifically, the thickness of the wear-resistant layer 30 at the corner 60 of the click-lock floor does not show a monotonically changing trend when measured in the vertical direction, and the relative range of the thickness does not exceed 20%, 15%, 10%, or 5%. Here, the relative range of thickness refers to the thickness range divided by the average thickness, that is, the difference between the maximum thickness and the minimum thickness divided by the average thickness.

[0058] Furthermore, for WPC flooring, the LVT layer at the corner 60 has a uniform thickness measured in the vertical direction. Compared to the LVT layer becoming thinner towards the outer edge of the corner 60, this uniform thickness ensures high consistency across the corner 60 and even the entire click-lock flooring, both in the extension direction and vertically. This results in a good appearance and guarantees the high quality and stability of the click-lock flooring. Specifically, the thickness of the LVT layer at the corner 60 of the click-lock flooring does not exhibit a monotonically changing trend when measured in the vertical direction, and the relative range of thickness does not exceed 20%, 15%, 10%, or 5%.

[0059] It should be noted that the uniform thickness mentioned in this invention refers to the thickness after the corner portion 60 is trimmed to form the final shape, which does not contradict the thinning of the outer thickness during the extrusion deformation process. That is, during the extrusion deformation process, the thickness of the part of the corner portion 60 near the main body 50 is as consistent as possible, while the part away from the main body 50 may become thinner. After trimming the corner portion 60, the thickness of the layers of the corner portion 60 in the final shape is basically consistent.

[0060] Preferably, with the horizontal direction as the x-axis and the vertical direction as the y-axis, the upper surface contours of the wear-resistant layer 30, the color filter layer 20, and the substrate layer 10 at the corner 60 respectively conform to polynomial functions. More preferably, with the horizontal direction as the x-axis and the vertical direction as the y-axis, the upper surface contours of the wear-resistant layer 30, the color filter layer 20, and the substrate layer 10 at the corner 60 respectively conform to cubic polynomial functions. Even more preferably, the coefficient of determination R of the cubic polynomial function fitted to the upper surface contours of the wear-resistant layer 30, the color filter layer 20, and the substrate layer 10 at the corner 60 is... 2 Greater than 0.95, greater than 0.97, greater than 0.98, or greater than 0.99. Specifically, taking the adjacent point of the main body 50 and the corner portion 60 of the click-lock floor as the origin, with the horizontal direction as the x-axis and the vertical direction as the y-axis, the upper surface contours of the wear-resistant layer 30, the upper surface contours of the color film layer 20, and the upper surface contours of the substrate layer 10 at the corner portion 60 are designed to conform to a polynomial function or a further cubic polynomial function. In terms of the actual product, after the product is formed and processed, the cross-sectional contour values ​​at the corner portion 60 are taken at intervals, and the coefficient of determination R of the fitted cubic polynomial function is... 2 Greater than 0.95, greater than 0.97, greater than 0.98, or greater than 0.99. The inventors of this invention have studied and compared experiments and found that the surface profile at the corner 60, which conforms to a polynomial function or a further cubic polynomial function, has a smoother, more beautiful, and more delicate splicing appearance compared to surface profiles of other shapes (especially compared to pure arc-shaped surface profiles).

[0061] The following describes the locking floor according to the present invention through examples of specific products.

[0062] Example 1: SPC Flooring

[0063] With the adjacent point of the main body 50 and the corner portion 60 of the locking floor as the origin, the horizontal direction as the x-axis and the vertical direction as the y-axis, the coordinates of each layer of the SPC floor according to Example 1 of the present invention are shown in Table 1.

[0064] Based on the coordinates of each point in Table 1, the thickness of the wear layer 30 of the SPC flooring according to Example 1 of the present invention can be calculated and plotted. Figure 4 According to calculations, the relative range of the thickness of the wear-resistant layer 30 at the corner 60 of the SPC floor according to Example 1 of the present invention, measured in the vertical direction, is 14.96%.

[0065] Additionally, the upper surface contours of the wear-resistant layer 30 at the corner 60, the upper surface contours of the color filter layer 20, and the upper surface contours of the substrate layer 10 can be fitted with polynomial functions or further cubic polynomial functions, respectively, and plotted as follows: Figure 10 According to the fitting, the coefficient of determination R of the cubic polynomial function fitted to the upper surface profile of the wear-resistant layer 30, the upper surface profile of the color film layer 20, and the upper surface profile of the substrate layer 10 at the corner 60 of the SPC floor according to Example 1 of the present invention is... 2 The values ​​are 0.997, 0.995, and 0.995, respectively.

[0066] Table 1 - Coordinates of each layer of the SPC floor according to Example 1 of the present invention

[0067]

[0068] Example 2: SPC Flooring

[0069] With the adjacent point of the main body 50 and the corner portion 60 of the locking floor as the origin, the horizontal direction as the x-axis and the vertical direction as the y-axis, the coordinates of each layer of the SPC floor according to Example 2 of the present invention are shown in Table 2.

[0070] Based on the coordinates of each point in Table 2, the thickness of the wear layer 30 of the SPC flooring according to Example 2 of the present invention can be calculated and plotted. Figure 5 According to calculations, the relative range of the thickness of the wear-resistant layer 30 at the corner 60 of the SPC floor according to Example 2 of the present invention, measured in the vertical direction, is 16.39%.

[0071] Additionally, the upper surface contours of the wear-resistant layer 30 at the corner 60, the upper surface contours of the color filter layer 20, and the upper surface contours of the substrate layer 10 can be fitted with polynomial functions or further cubic polynomial functions, respectively, and plotted as follows: Figure 11According to the fitting, the coefficient of determination R of the cubic polynomial function fitted to the upper surface profile of the wear-resistant layer 30, the upper surface profile of the color film layer 20, and the upper surface profile of the substrate layer 10 at the corner 60 of the SPC floor according to Example 2 of the present invention is... 2 The values ​​are 0.998, 0.992, and 0.993, respectively.

[0072] Table 2 - Coordinates of each layer of the SPC floor according to Example 2 of the present invention

[0073]

[0074] Example 3: WPC Flooring

[0075] With the point of contact between the main body 50 and the corner portion 60 of the locking floor as the origin, the horizontal direction as the x-axis, and the vertical direction as the y-axis, the coordinates of each layer of the WPC floor according to Example 3 of the present invention are shown in Table 3. Since the thickness of the color film layer 20 is relatively small compared to the thickness of the LVT layer, the thickness of the color film layer 20 is ignored in this example.

[0076] Based on the coordinates of each point in Table 3, the thickness of the wear layer 30 of the WPC floor according to Example 3 of the present invention can be calculated and plotted. Figure 6 According to calculations, the relative range of the thickness of the wear-resistant layer 30 at the corner 60 of the WPC flooring according to Example 3 of the present invention, measured in the vertical direction, is 11.00%. Furthermore, the thickness of the LVT layer of the WPC flooring according to Example 3 of the present invention can be calculated and plotted... Figure 8 According to calculations, the relative range of the thickness of the LVT layer at the corner 60 of the WPC floor according to Example 3 of the present invention, measured in the vertical direction, is 3.73%.

[0077] Additionally, the upper surface contours of the wear-resistant layer 30 at the corner 60, the upper surface contours of the color filter layer 20, and the upper surface contours of the substrate layer 10 can be fitted with polynomial functions or further cubic polynomial functions, respectively, and plotted as follows: Figure 12 According to the fitting, the coefficient of determination R of the cubic polynomial function fitted to the upper surface profile of the wear-resistant layer 30, the upper surface profile of the color film layer 20, and the upper surface profile of the substrate layer 10 at the corner 60 of the WPC floor according to Example 3 of the present invention is... 2 The values ​​are 0.994, 0.995, and 0.987, respectively.

[0078] Table 3 - Coordinates of each layer of the WPC floor according to Example 3 of the present invention

[0079]

[0080] Example 4: WPC Flooring

[0081] With the point of contact between the main body 50 and the corner portion 60 of the locking floor as the origin, the horizontal direction as the x-axis, and the vertical direction as the y-axis, the coordinates of each layer of the WPC floor according to Example 4 of the present invention are shown in Table 4. Since the thickness of the color film layer 20 is relatively small compared to the thickness of the LVT layer, the thickness of the color film layer 20 is ignored in this example.

[0082] Based on the coordinates of each point in Table 4, the thickness of the wear layer 30 of the WPC floor according to Example 4 of the present invention can be calculated and plotted. Figure 7 According to calculations, the relative range of the thickness of the wear-resistant layer 30 at the corner 60 of the WPC flooring in Example 4 of the present invention, measured in the vertical direction, is 14.24%. Furthermore, the thickness of the LVT layer of the WPC flooring in Example 3 of the present invention can be calculated and plotted... Figure 8 According to calculations, the relative range of the thickness of the LVT layer at the corner 60 of the WPC floor according to Example 3 of the present invention, measured in the vertical direction, is 8.37%.

[0083] Additionally, the upper surface contours of the wear-resistant layer 30 at the corner 60, the upper surface contours of the color filter layer 20, and the upper surface contours of the substrate layer 10 can be fitted with polynomial functions or further cubic polynomial functions, respectively, and plotted as follows: Figure 13 According to the fitting, the coefficient of determination R of the cubic polynomial function fitted to the upper surface profile of the wear-resistant layer 30, the upper surface profile of the color film layer 20, and the upper surface profile of the substrate layer 10 at the corner 60 of the WPC floor according to Example 4 of the present invention is... 2 The values ​​are 0.991, 0.984, and 0.988, respectively.

[0084] Table 4 - Coordinates of each layer of the WPC floor according to Example 4 of the present invention

[0085]

[0086] The exemplary embodiments of the locking floor proposed by the present invention have been described in detail above with reference to preferred embodiments. However, those skilled in the art will understand that various modifications and alterations can be made to the above specific embodiments without departing from the concept of the present invention, and various combinations can be made to the various technical features and structures proposed by the present invention without exceeding the protection scope of the present invention.

Claims

1. A click-lock floor, comprising the following structural layers: A substrate layer, with a locking portion formed thereon; Color filter layer above the substrate layer; A wear-resistant layer above the color filter layer; as well as The UV layer above the wear-resistant layer, Each structural layer forms a main body extending horizontally and corner portions formed at the corners of the main body, which curve downwards and bevel. The wear-resistant layer at the corners of the locking floor has a uniform thickness measured in the vertical direction.

2. The locking floor according to claim 1, wherein, The locking floor also includes an LVT layer between the substrate layer and the color film layer, and the LVT layer at the corners of the locking floor has a uniform thickness measured in the vertical direction.

3. The locking floor according to claim 1 or 2, wherein, The relative range of the thickness of the wear-resistant layer at the corners of the locking floor, measured in the vertical direction, does not exceed 20%.

4. The locking floor according to claim 2, wherein, The relative range of the thickness of the LVT layer at the corners of the locking floor, measured in the vertical direction, does not exceed 20%.

5. The click-lock flooring according to claim 1 or 2, wherein, With the horizontal direction as the x-axis and the vertical direction as the y-axis, the upper surface contours of the wear-resistant layer, the upper surface contours of the color filter layer, and the upper surface contours of the substrate layer at the corners respectively conform to a polynomial function.

6. The locking floor according to claim 1 or 2, wherein, With the horizontal direction as the x-axis and the vertical direction as the y-axis, the upper surface contours of the wear-resistant layer, the upper surface contours of the color filter layer, and the upper surface contours of the substrate layer at the corners respectively conform to a cubic polynomial function.

7. The locking floor according to claim 6, wherein, The coefficient of determination of the cubic polynomial function fitted to the upper surface profile of the wear-resistant layer, the upper surface profile of the color filter layer, and the upper surface profile of the substrate layer at the corners is greater than 0.

95.

8. The click-lock flooring according to claim 1 or 2, wherein, The structural layers at the corners of the locking floor are formed by extrusion deformation.

9. The locking floor according to claim 8, wherein, The structural layers at the corners of the locking floor are formed by extrusion deformation using a pressure roller, the outer contour of which is circular.

10. The locking floor according to claim 9, wherein, The structural layers at the corners of the locking floor are formed by the overall deformation of the material by using a pressure roller and then allowing it to spring back.

11. The locking floor according to claim 8, wherein, The corners are heated and softened before being extruded and deformed.

12. The locking floor according to claim 8, wherein, The corners are cut vertically after being extruded and deformed to form the final shape.

13. A method for forming a click-lock floor according to any one of claims 1-12, comprising the following steps: Forming each structural layer; Heating softens the edges and corners of the floor; The corners and edges are formed integrally by extrusion deformation, including downward bending and chamfering transitions of each structural layer; and Cut the corners vertically to form the final shape of the corners.

14. The forming process of the locking floor according to claim 13 further includes performing locking processing after cutting off the corners.

Images