High covering lightweight spc wallboard and preparation method thereof

Abstract

The application discloses a kind of high covering light SPC wallboards and preparation method thereof, it is related to SPC wallboard technical field, from top to bottom include in turn: wear-resistant layer, color film, bottom film layer and foamed substrate layer;The bottom film layer is white covering film, the bottom film layer is set between the color film and the foamed substrate layer;The application is added between color film and foamed substrate layer by a layer of high covering bottom film layer, effectively covers substrate color difference using the high covering performance of bottom film layer, so that product surface color is consistent, is not affected by substrate color difference.Compared with conventional light SPC wallboard, the application does not need to spend a lot of time adjusting substrate color, reduces material waste in the adjustment process, significantly improves production efficiency, reduces production cost.

Description

Technical Field

[0001] This invention relates to the field of SPC wall panel technology, and in particular to a high-coverage lightweight SPC wall panel and its preparation method. Background Technology

[0002] Currently, lightweight SPC wall panels on the market suffer from unstable substrate colors due to formulation issues, resulting in frequent color variations on the surface and wasting time adjusting the color. Existing lightweight SPC wall panels typically have a three-layer structure: a wear-resistant layer, a color film, and a lightweight SPC substrate. The color film is directly bonded to the substrate surface, and color differences in the substrate are directly reflected through the color film onto the product surface, leading to inconsistent surface colors. When color differences occur in the substrate due to formulation fluctuations, raw material batch variations, or changes in production processes, significant time and materials are required to adjust the substrate color, severely impacting production efficiency and cost control. Furthermore, the adjusted substrate color may still fluctuate, making it difficult to guarantee long-term stability of the product's surface color. Summary of the Invention

[0003] Purpose of the invention: The purpose of this invention is to provide a high-coverage lightweight SPC wall panel and its preparation method, thereby solving the problems in the existing wall panel manufacturing process.

[0004] Technical solution: A high-coverage lightweight SPC wall panel, comprising, from top to bottom: a wear-resistant layer, a colored film, a base film layer, and a foamed substrate layer;

[0005] The bottom film layer is a white cover film, and the bottom film layer is disposed between the colored film and the foamed substrate layer.

[0006] Preferably, the wear-resistant layer has a thickness of 0.07-0.10 mm, the color film layer has a thickness of 0.07 mm, the base film layer has a thickness of 0.07-0.10 mm, and the foamed substrate layer has a thickness of 3.5-4.5 mm.

[0007] Preferably, the bottom film layer is composed of the following components in parts by weight: 120 parts PVC resin; 3-5 parts methyl tin stabilizer; 10-20 parts titanium dioxide; 3-5 parts processing aid; 6-8 parts talc; 6-8 parts calcium powder; 7-10 parts barium sulfate; 0.4-0.8 parts antioxidant; 0.7-1.2 parts internal lubricant; 1-1.4 parts external lubricant; 3-8 parts impact modifier; and 0.01 parts carbon black.

[0008] Preferably, the titanium dioxide is rutile titanium dioxide.

[0009] Preferably, the carbon black is channel black.

[0010] Preferably, the calcium powder is 1000-mesh ultra-white calcium powder.

[0011] Preferably, the barium sulfate is precipitated barium sulfate.

[0012] Preferably, a sound-absorbing layer is attached to the back of the foamed substrate layer. The sound-absorbing layer is selected from IXPE, IXPP or EVA and is bonded to the foamed substrate layer with PUR adhesive.

[0013] A method for preparing a high-coverage lightweight SPC wall panel, used in the above-mentioned high-coverage lightweight SPC wall panel, includes the following steps:

[0014] (1) Preparation of base film: Weigh each component of the base film according to the mass fraction, add it into a high-speed mixer and heat it to 100℃-110℃ to mix evenly; feed the material into a cold pot and start low-speed stirring. Set the temperature of the cold pot to 40℃-50℃. After the mixture reaches the specified temperature, put it into the silo; feed the mixture in the silo into the planetary extruder through the feeder for plasticization; calender the plasticized material through multiple sets of rollers of the calender to gradually extend it into a white film; cool and shape the calendered white film through a cooling device.

[0015] (2) Preparation of foamed substrate layer: Polyvinyl chloride resin and foaming agent are added to a mixer and mixed in a high-speed mixer to 110℃-130℃. Then, the mixture is stirred and cooled to 50℃-60℃ to obtain a mixture. The mixture is placed in a twin-screw foaming screw and foamed and plasticized at 160℃-200℃. It is then extruded through a mold and the thickness of the extruded substrate is controlled by upper and lower double mirror pressure rollers to obtain a substrate of fixed thickness.

[0016] (3) Composite: The wear-resistant layer, color film, base film and fixed thickness substrate layer are thermally bonded to the steel roller online by a rubber roller. The temperature of the steel roller is 160℃-170℃ to obtain a semi-finished product;

[0017] (4) Surface treatment: The above semi-finished products are coated with UV-curable coating by roller coating and then cured with UV light;

[0018] (5) Post-processing: Segment and groove to obtain high-coverage SPC wall panels.

[0019] Preferably, in step (3), before the online thermal bonding, an IXPE, IXPP or EVA sound-absorbing layer is bonded to the back of the foamed substrate layer using PUR adhesive.

[0020] Beneficial Effects: This invention adds a high-opacity base film layer between the colored film and the foamed substrate layer. The high opacity of the base film layer effectively masks color differences in the substrate, ensuring a consistent product surface color unaffected by substrate color variations. Compared to conventional lightweight SPC wall panels, this invention eliminates the need for extensive substrate color adjustments, reducing material waste and significantly improving production efficiency and costs. Furthermore, even with significant differences in lightweight SPC substrate development, this invention maintains a similar product surface color, with a surface color difference ΔE controlled within 0.5, meaning no noticeable change to the naked eye. This is far lower than the surface color difference of conventional lightweight SPC wall panels (ΔE within 2, indicating significant color difference), fully meeting customer requirements for consistent product surface color. In addition, the base film layer is formed using a calendering process and is thermally bonded online with the wear-resistant layer, colored film, and substrate, resulting in a simple, efficient, and easily industrialized process. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the overall structure of the present invention.

[0022] Figure reference numerals: 1. Wear-resistant layer; 2. Color film; 3. Base film layer; 4. Foamed substrate layer. Detailed Implementation

[0023] To make the technical solution of the present invention clearer, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0024] Example

[0025] Benru Figure 1 As shown, this invention provides a high-coverage lightweight SPC wall panel, comprising, from top to bottom, a wear-resistant layer 1, a color film 2, a base film layer 3, and a foamed substrate layer 4. The wear-resistant layer 1 is a transparent wear-resistant layer with a thickness of 0.07-0.10 mm, preferably 0.08 mm, used to protect the color film 2 and improve the wear resistance of the wall panel surface. The color film 2 is a decorative layer with a thickness of 0.07 mm, used to provide patterns and colors on the wall panel surface. The base film layer 3 is a calendered white cover film, disposed between the color film 2 and the foamed substrate layer 4, with a thickness of 0.07-0.10 mm, preferably 0.08 mm. Its main function is to cover color differences in the foamed substrate layer 4, ensuring a consistent product surface color unaffected by substrate color differences. The foamed substrate layer 4 is a lightweight SPC substrate with a thickness of 3.5-4.5 mm, preferably 4.0 mm, made from polyvinyl chloride resin and a foaming agent through a foaming process, possessing lightweight, sound insulation, and heat insulation properties. The back of the foamed substrate layer 4 can be fitted with a sound-absorbing layer 5 as needed. The sound-absorbing layer 5 is selected from IXPE, IXPP or EVA and is bonded to the foamed substrate layer 4 with PUR adhesive to improve the sound insulation effect and foot comfort of the wall panel.

[0026] The base film layer 3 is composed of the following components in parts by weight: 120 parts PVC resin; 3-5 parts methyl tin stabilizer; 10-20 parts titanium dioxide; 3-5 parts processing aids; 6-8 parts talc; 6-8 parts calcium carbonate; 7-10 parts barium sulfate; 0.4-0.8 parts antioxidant; 0.7-1.2 parts internal lubricant; 1-1.4 parts external lubricant; 3-8 parts impact modifier; and 0.01 parts carbon black. The titanium dioxide is preferably rutile titanium dioxide, which has a higher refractive index than anatase titanium dioxide, resulting in stronger hiding power and effective light scattering, thus improving the whiteness and hiding performance of the base film. The carbon black is preferably channel black, which is beneficial for dispersion and coloring, and can absorb a small amount of unscattered transmitted light, further improving the hiding effect. The calcium carbonate is preferably 1000-mesh ultra-white calcium carbonate, which ensures the color consistency of the base film and reduces material costs. The barium sulfate is preferably prepared by precipitation. The precipitated barium sulfate has uniform fineness, high whiteness, low oil absorption, and strong chemical stability. It can act as a physical separator in the formulation, greatly reducing [oil consumption]. The aggregation of particles improves hiding power. The PVC resin, processing aids, methyltin stabilizer, talc, antioxidant, internal lubricant, external lubricant, and impact modifier are conventional raw materials and can be commercially available products commonly used in the field.

[0027] The present invention also provides a method for preparing the above-mentioned high-coverage lightweight SPC wall panel, comprising the following steps: base film preparation: weigh each component of the base film according to the mass fraction, add it into a high-speed mixer, heat it to 100℃-110℃, and mix it evenly; feed the material into a cold pot and start low-speed stirring, set the temperature of the cold pot to 40℃-50℃, and after the mixture reaches the specified temperature, put it into the silo; feed the mixture in the silo into a planetary extruder for plasticization through a feeder; calender the plasticized material through multiple sets of rollers of a calender to gradually extend it into the required white film; cool and shape the calendered white film through a cooling device to ensure product dimensional stability and surface flatness. Preparation of foamed substrate layer: Polyvinyl chloride resin and foaming agent are added to a mixer and mixed at 110℃-130℃ in a high-speed mixer, then stirred and cooled to 50℃-60℃ to obtain a mixture. The mixture is placed in a twin-screw foaming screw and foamed and plasticized at 160℃-200℃. It is then extruded through a die, and the thickness of the extruded substrate is controlled by upper and lower double mirror pressure rollers to obtain a fixed-thickness substrate. Lamination: The wear-resistant layer 1, color film 2, base film layer 3, and fixed-thickness substrate layer 4 are thermally bonded online to a steel roller using a rubber roller at a temperature of 160℃-170℃ to obtain a semi-finished product. Before online thermal bonding, an IXPE, IXPP, or EVA sound-absorbing layer 5 can be bonded to the back of the foamed substrate layer 4 using PUR adhesive as needed. Surface treatment: The above semi-finished product is coated with a UV-curable coating by roller coating and then UV-cured to improve the wear resistance and stain resistance of the wall panel surface. Post-processing: The panels are divided into sections and grooved to obtain high-coverage SPC wall panels.

[0028] The present invention will be further illustrated by specific embodiments below, but the scope of protection of the present invention is not limited thereto.

[0029] Example 1: The formulation of the base film layer 3 is as follows: 120 parts PVC resin; 4 parts methyltin stabilizer; 15 parts rutile titanium dioxide; 4 parts processing aid; 7 parts talc; 7 parts 1000-mesh super white calcium powder; 8 parts precipitated barium sulfate; 0.6 parts antioxidant; 0.9 parts internal lubricant; 1.2 parts external lubricant; 5 parts impact modifier; and 0.01 parts channel black. The wear-resistant layer 1 has a thickness of 0.08 mm, the color film 2 has a thickness of 0.07 mm, the base film layer 3 has a thickness of 0.08 mm, and the foamed substrate layer 4 has a thickness of 4.0 mm. The preparation method is as described in steps one to five above. Testing revealed that the high-coverage lightweight SPC wall panel prepared in this embodiment, despite significant differences in the development of lightweight SPC substrates, still maintains a high degree of color consistency on the product surface. The surface color difference ΔE is controlled within 0.5, which is within the range where there is no obvious change to the naked eye. This is far lower than the surface color difference of conventional lightweight SPC wall panels (ΔE is within 2, with obvious surface color difference).

[0030] Example 2: The formulation of the base film layer 3 is as follows: 120 parts PVC resin; 3 parts methyltin stabilizer; 10 parts rutile titanium dioxide; 3 parts processing aid; 6 parts talc; 6 parts 1000-mesh super white calcium powder; 7 parts precipitated barium sulfate; 0.4 parts antioxidant; 0.7 parts internal lubricant; 1 part external lubricant; 3 parts impact modifier; and 0.01 parts channel black. The wear-resistant layer 1 is 0.07 mm thick, the color film 2 is 0.07 mm thick, the base film layer 3 is 0.07 mm thick, and the foamed substrate layer 4 is 3.5 mm thick. The preparation method is the same as in Example 1. Testing showed that the surface color difference ΔE of the product was controlled within the range of 0.48-1.73.

[0031] Example 3: The formulation of the base film layer 3 is as follows: 120 parts PVC resin; 5 parts methyltin stabilizer; 20 parts rutile titanium dioxide; 5 parts processing aid; 8 parts talc; 8 parts 1000-mesh super white calcium powder; 10 parts precipitated barium sulfate; 0.8 parts antioxidant; 1.2 parts internal lubricant; 1.4 parts external lubricant; 8 parts impact modifier; and 0.01 parts channel black. The wear-resistant layer 1 is 0.10 mm thick, the color film 2 is 0.07 mm thick, the base film layer 3 is 0.10 mm thick, and the foamed substrate layer 4 is 4.5 mm thick. The preparation method is the same as in Example 1. Testing showed that the surface color difference ΔE of the product was controlled within the range of 0.20-1.20.

[0032] Comparative Example: Conventional lightweight SPC wall panels have a structure of a wear-resistant layer + color film + lightweight SPC substrate, excluding the base film layer. When there is a significant color difference in the substrate, the surface color difference ΔE of the conventional lightweight SPC wall panel is within 2, which is far greater than that of the high-opacity lightweight SPC wall panel of this invention.

[0033] This invention adds a bottom film layer between the colored film and the foamed substrate layer. Utilizing the high opacity of the bottom film layer, it effectively masks color differences in the substrate, resulting in a consistent product surface color. Compared to conventional lightweight SPC wall panels, this invention eliminates the need for extensive time spent adjusting the substrate color, reducing material waste during the adjustment process, improving production efficiency, and simultaneously meeting customers' requirements for consistent product surface color.

[0034] The above describes specific embodiments of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

[0035] The embodiments described above are merely illustrative of several implementations of the present invention, and while the descriptions are specific and detailed, they should not be construed as limiting the scope of the present invention. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these modifications and improvements all fall within the scope of protection of the present invention. Therefore, the scope of protection of this patent should be determined by the appended claims.

Claims

1. A high-coverage lightweight SPC wall panel, characterized in that, From top to bottom, it includes: a wear-resistant layer, color film, base film layer, and foamed substrate layer; The bottom film layer is a white cover film, and the bottom film layer is disposed between the colored film and the foamed substrate layer.

2. The high-coverage lightweight SPC wall panel according to claim 1, characterized in that, The wear-resistant layer has a thickness of 0.07-0.10 mm, the color film layer has a thickness of 0.07 mm, the base film layer has a thickness of 0.07-0.10 mm, and the foamed substrate layer has a thickness of 3.5-4.5 mm.

3. The high-coverage lightweight SPC wall panel according to claim 1, characterized in that, The base film layer is composed of the following components in parts by weight: 120 parts PVC resin; 3-5 parts methyl tin stabilizer; 10-20 parts titanium dioxide; 3-5 parts processing aid; 6-8 parts talc; 6-8 parts calcium powder; 7-10 parts barium sulfate; 0.4-0.8 parts antioxidant; 0.7-1.2 parts internal lubricant; 1-1.4 parts external lubricant; 3-8 parts impact modifier; and 0.01 parts carbon black.

4. The high-coverage lightweight SPC wall panel according to claim 3, characterized in that, The titanium dioxide is rutile titanium dioxide.

5. The high-coverage lightweight SPC wall panel according to claim 3, characterized in that, The carbon black is channel black.

6. The high-coverage lightweight SPC wall panel according to claim 3, characterized in that, The calcium powder is 1000-mesh ultra-white calcium powder.

7. The high-coverage lightweight SPC wall panel according to claim 3, characterized in that, The barium sulfate mentioned is barium sulfate produced by precipitation.

8. The high-coverage lightweight SPC wall panel according to claim 1, characterized in that, A sound-absorbing layer is attached to the back of the foamed substrate layer. The sound-absorbing layer is selected from IXPE, IXPP or EVA and is bonded to the foamed substrate layer with PUR adhesive.

9. A method for preparing a high-coverage lightweight SPC wall panel, characterized in that, Includes the following steps: (1) Preparation of base film: Weigh each component of the base film according to the mass fraction, add it into a high-speed mixer and heat it to 100℃-110℃ to mix evenly; feed the material into a cold pot and start low-speed stirring. Set the temperature of the cold pot to 40℃-50℃. After the mixture reaches the specified temperature, put it into the silo; feed the mixture in the silo into the planetary extruder through the feeder for plasticization; calender the plasticized material through multiple sets of rollers of the calender to gradually extend it into a white film; cool and shape the calendered white film through a cooling device. (2) Preparation of foamed substrate layer: Polyvinyl chloride resin and foaming agent are added to a mixer and mixed at 110℃-130℃ in a high-speed mixer. Then, the mixture is stirred and cooled to 50℃-60℃ to obtain a mixture. The mixture is placed in a twin-screw foaming screw and foamed and plasticized at 160℃-200℃. The mixture is then extruded through a die, and the extruded substrate is passed through the upper and lower screws. Double-mirror pressure rollers control the thickness to obtain a substrate of constant thickness; (3) Composite: The wear-resistant layer, color film, base film and fixed thickness substrate layer are thermally bonded to the steel roller online by a rubber roller. The temperature of the steel roller is 160℃-170℃ to obtain a semi-finished product; (4) Surface treatment: The above semi-finished products are coated with UV-curable coating by roller coating and then cured with UV light; (5) Post-processing: Segment and groove to obtain high-coverage SPC wall panels.

10. The preparation method according to claim 9, characterized in that, Before the online thermal bonding in step (3), the IXPE, IXPP or EVA sound-absorbing layer is bonded to the back of the foamed substrate layer with PUR adhesive.

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