Fast-assembled and fast-disassembled floor with invisible buckle tooth multi-structure and preparation method and paving method thereof

Abstract

This invention discloses a multi-structure quick-install and quick-remove flooring with concealed interlocking teeth. It is composed of a decorative surface layer and a toothed base layer with interlocking teeth, bonded together with an adhesive layer in a staggered manner. Both the decorative surface layer and the toothed base layer are independently molded sheet semi-finished products. The interlocking teeth are formed by punching or milling on the toothed base layer. The decorative surface layer is horizontally staggered relative to the toothed base layer, so that the interlocking teeth on adjacent sides of the toothed base layer are hidden beneath the decorative surface layer, while the interlocking teeth on the other two sides extend beyond the edge of the decorative surface layer, forming an L-shaped overlap. During installation, the interlocking teeth of adjacent floorboards are pressed vertically down to achieve quick splicing without glue or hammering. The adhesive layer reserved at the exposed interlocking points further bonds the interlocking teeth of adjacent floorboards, preventing edge lifting, simplifying disassembly, and allowing for reuse. This invention combines the advantages of convenient installation of adhesive-backed flooring and glue-free splicing of toothed flooring, while avoiding all the drawbacks of both.

Description

Technical Field

[0001] This invention belongs to the field of building decoration materials technology, specifically relating to an elastic floor, and more particularly to a multi-structure quick-install and quick-remove floor with invisible interlocking teeth, as well as its preparation method and installation method. Background Technology

[0002] Polyvinyl chloride (PVC) sheet flooring (known in the industry as LVT flooring) is widely used in residential and commercial spaces for floor decoration due to its waterproof, slip-resistant, wear-resistant, comfortable feel, and rich variety of colors and patterns. Currently, there are three main types of installation methods for commercially available LVT sheet flooring:

[0003] The first category is adhesive-backed products or floor adhesives applied on-site. Adhesive-backed products have a hot-melt pressure-sensitive adhesive pre-coated on the back and a release liner applied before leaving the factory. During installation, the release liner is removed and the product is directly adhered to the floor. On-site adhesive products, however, involve applying the floor adhesive to the ground before installation. The problems with this type of product are: First, in adhesive-backed products, the plasticizer at the bottom of the product gradually migrates and seeps into the hot-melt pressure-sensitive adhesive on the back as logistics and storage time increase, weakening or even causing the adhesive strength to decrease and potentially leading to adhesive spillage across the four cut surfaces of the product. The release effect of the release liner deteriorates after the plasticizer leaches out, resulting in sticky adhesive and contamination of the product's surface during installation. Second, after a period of use, the adhesive becomes firmly bonded to the floor, making it difficult to remove without damage and preventing reuse. Third, on-site application requires a high level of skill from the installer, considering the construction environment, the quality of the floor adhesive, and the installer's technical expertise. It also requires waiting time, has a long construction period, and produces volatile odors.

[0004] The second type is traditional mortise and tenon click flooring. This type of product does not require glue during installation, but it has high requirements for the flatness of the ground, usually requiring self-leveling treatment beforehand. Installation requires special tools, and tapping the click joints can easily generate noise. After long-term use, the mortise and tenon joints are prone to breakage and disassembly. They are difficult to repair locally after installation, and the mortise and tenon joints are easily damaged during removal, making them unsuitable for repeated use.

[0005] The third type is the one-piece molded convex-concave buckle product. This type of product has a novel appearance and does not require a large area of ​​glue during installation. However, each buckle still needs to be tapped during installation, which is noisy. It has high requirements for product thickness. Even a slight deviation will cause height differences at the buckle, affecting the installation effect and creating safety hazards. In order to achieve no obvious splicing gaps at the joint, the buckles are usually made to bite tightly. This causes material debris to be knocked out during assembly. After the debris gets stuck in the buckle, it causes deformation at the buckle and unevenness of the overall paving. Moreover, it is laborious and inconvenient to remove and reuse.

[0006] Therefore, there is an urgent need for a flooring product and its preparation method that can be installed quickly without glue, spliced ​​without knocking and without noise, and disassembled and reused without damage. Summary of the Invention

[0007] To address the aforementioned shortcomings of existing technologies, the present invention aims to provide a multi-structure quick-install and quick-remove floor with invisible interlocking teeth, along with its preparation and installation methods. Through a product structure and process route involving separate preform preparation, die-cutting, and staggered adhesive bonding, it combines the advantages of adhesive-backed flooring (no on-site gluing required) and interlocking teeth products (adhesive-free splicing). Simultaneously, it overcomes the drawbacks of adhesive-backed products (plasticizer migration, difficulty in removal), and interlocking / irregular-shaped interlocking products (high flatness requirements, need for hammering, material debris, and difficulty in secondary use).

[0008] To achieve the above objectives, the technical solution adopted by the present invention is as follows.

[0009] The multi-structure quick-install and quick-remove flooring with concealed interlocking teeth includes a decorative surface layer, an interlocking tooth base layer, and an adhesive layer. The decorative surface layer is a separately formed sheet, comprising at least a transparent wear-resistant layer, a printed decorative layer, and a composite base layer from top to bottom. The interlocking tooth base layer is also a separately formed sheet, located below the decorative surface layer. The edges of the interlocking tooth base layer are provided with concave and convex interlocking teeth, which are obtained by punching or milling the interlocking tooth base layer. The adhesive layer is disposed between the decorative surface layer and the interlocking tooth base layer, bonding the decorative surface layer and the interlocking tooth base layer into one unit. The decorative surface layer is horizontally offset relative to the interlocking tooth base layer, so that the concave and convex interlocking teeth on two adjacent sides of the interlocking tooth base layer are covered below the decorative surface layer to form concealed interlocking teeth. The concave and convex interlocking teeth on the other two sides opposite to the two adjacent sides extend beyond the edge of the decorative surface layer to form an L-shaped exposed overlapping edge.

[0010] Furthermore, the decorative surface layer also includes a surface UV layer disposed on the upper surface of the transparent wear-resistant layer, and / or a composite intermediate layer disposed between the printed decorative layer and the composite base layer.

[0011] Furthermore, chopped glass fibers are dispersedly added to the composite intermediate layer and / or the composite base layer, the length of the chopped glass fibers being 0.05mm-20mm and the weight percentage being 1%-15%; or, the decorative surface layer further includes a glass fiber layer, the glass fiber layer being a mesh-like glass fiber or impregnated glass fiber cloth, with a basis weight of 20g / m²-500g / m², disposed between the composite intermediate layer and the composite base layer.

[0012] Furthermore, the transparent wear-resistant layer and the printed decorative layer may be replaced by any of the following structures: a homogeneous through-layer; a PVC woven material layer; or a combination of a wear-resistant impregnated paper layer and a printed decorative layer; the width of the floor is 50mm-2500mm and the length is 50mm-2500mm.

[0013] Furthermore, a barrier film is provided between the decorative surface layer and the adhesive layer. The barrier film is a polyvinyl chloride film containing plasticizer, with a thickness of 0.02mm-1.0mm, used to prevent the plasticizer in the composite base layer from migrating to the adhesive layer.

[0014] Furthermore, the concave and convex buckles are any one of elliptical buckles, circular buckles, concave buckles, or swallowtail buckles; the number of concave and convex buckles on each floorboard is 1-100, the biting angle of the swallowtail buckles is 45°-65°, and the radius of the root transition rounded corner is 2mm-5mm.

[0015] Furthermore, the adhesive layer is selected from hot melt adhesive layer, polyurethane reactive adhesive layer, two-component adhesive layer, white latex layer or all-purpose adhesive layer, with a coating amount of 10g / m²-500g / m²; the adhesive layer remaining at the recessed part of the interlocking teeth extending beyond the edge of the decorative surface layer constitutes an auxiliary adhesive part for bonding adjacent floorboards during installation.

[0016] Furthermore, it also includes a sound-absorbing layer, which is attached to the top surface of the adhesive layer or the bottom surface of the tooth base layer. The material of the sound-absorbing layer is cross-linked polyethylene foam, foamed EVA, foamed PVC, non-woven fabric, flocked fabric or cork, and the thickness is 0.10mm-4.0mm.

[0017] Furthermore, the toothed base layer is selected from any of the following structures: a single-layer structure composed of a composite base layer; a composite structure composed of a composite intermediate layer and a composite base layer; a composite structure composed of a composite intermediate layer, a glass fiber layer, and a composite base layer; or a structure obtained by milling a rigid board, wherein the rigid board is selected from rigid PVC extruded board, extruded PVC foam board, thick non-woven fabric, plastic foam board, wood board, gypsum board, MDF, or rigid foam material board; the thickness of the toothed base layer is 1.0mm-6.0mm.

[0018] A method for preparing a multi-structure quick-installation and quick-removal floor with concealed interlocking teeth includes the following steps:

[0019] S1. Preparation of decorative surface layer semi-finished product: The transparent wear-resistant layer, printed decorative layer and composite base layer are stacked in sequence and formed by cold and hot pressing or extrusion composite molding into a decorative surface layer semi-finished product. After molding, UV coating tempering treatment and constant temperature curing treatment are carried out in sequence.

[0020] S2. Preparation of semi-finished products for toothed base layer: Mix the raw materials according to the ratio, knead them, calender them into sheets, or extrude them to obtain toothed base layer boards;

[0021] S3. Punching and forming: The decorative surface layer semi-finished product and the tooth base plate are punched and formed according to the preset size. During punching, concave and convex teeth are formed simultaneously on the edge of the tooth base plate. When the tooth base plate is a hard plate, concave and convex teeth are processed on its edge by precision milling.

[0022] S4. Adhesive backing: Apply adhesive to the back of the decorative surface layer, with a coating amount of 10g / m²-500g / m².

[0023] S5. Offset bonding: The decorative surface layer after applying adhesive is overlapped and pressed together with the interlocking tooth base layer according to a preset offset amount, so that the concave and convex interlocking teeth on the two adjacent sides of the interlocking tooth base layer are covered under the decorative surface layer to form hidden interlocking teeth. The concave and convex interlocking teeth on the other two sides opposite to the two adjacent sides extend beyond the edge of the decorative surface layer, and together with the edge of the decorative surface layer, they form an L-shaped exposed overlap edge, thus obtaining the multi-structure quick-installation and quick-removal floor with hidden interlocking teeth.

[0024] In step S5, a positioning fixture is used for misaligned bonding: the positioning fixture includes an L-shaped positioning plate and several backing blocks; the adjacent two sides of the buckle base layer are positioned against the inner edge of the L-shaped positioning plate, the backing blocks are placed on the buckle base layer, and then the decorative surface layer after being coated with adhesive is bonded to the backing blocks and pressed tightly onto the buckle base layer; the preset misalignment amount is: 0mm in the horizontal direction to half the product length, and 0mm in the vertical direction to half the product width.

[0025] In step S4, when hot melt adhesive is used, the heating oil temperature of the hot melt adhesive machine is set to 150℃-250℃, the coating steel roller temperature is set to 140℃-220℃, and the adhesive liquid temperature is 130℃-200℃; when polyurethane reactive adhesive is used, the heating pressure plate temperature is set to 130℃-180℃, the coating steel roller temperature is set to 140℃-220℃, and the adhesive liquid temperature is 100℃-150℃.

[0026] A method for installing a multi-structure quick-install and quick-remove floor with concealed interlocking teeth includes: laying a first floorboard flat on the surface to be installed; taking a second floorboard and aligning its exposed interlocking teeth with the corresponding interlocking teeth on the first floorboard in the horizontal plane, then pressing it vertically down to make the protruding teeth and concave teeth of the two floorboards interlock, thereby locking the two floorboards in the horizontal direction; the decorative surface layer of the second floorboard covers the interlocking teeth of the two floorboards, making the joint invisible from above; at the same time, the adhesive layer remaining at the L-shaped exposed overlapping edge bonds and fixes the interlocking teeth of the two adjacent floorboards.

[0027] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0028] First, during installation, no glue is needed on the ground or the back of the product. Adjacent floorboards can be joined by pressing down vertically with the interlocking teeth. The interlocking teeth base is relatively thin and the interlocking teeth are loosely engaged, so there is no need to knock hard, no noise is generated, and no debris is generated. After installation, there is no problem of deformation or unevenness caused by debris getting stuck in the interlocking teeth.

[0029] Secondly, the interlocking teeth of this invention have a moderate tightness, making disassembly effortless and non-destructive. The removed flooring can be reinstalled and reused, significantly improving the material recycling rate and reducing construction costs and environmental burden.

[0030] Third, the adhesive layer of this invention is located inside the product structure, with no adhesive or release paper on the back of the product. On the one hand, this avoids all the problems of plasticizer migration and contamination of the adhesive, sticky adhesive contamination of the front, and waste of release paper, and the product's storage and transportation cycle is not limited by the adhesive's lifespan. On the other hand, after the entire decorative surface layer is fully adhesiveted on the back, it is staggered and bonded to the interlocking base layer. A portion of adhesive naturally remains at the exposed recessed areas. This residual adhesive layer helps to bond the interlocking teeth of adjacent floorboards during installation, suppressing edge lifting caused by changes in ambient temperature and humidity, while also eliminating the need for a transitional adhesive release paper.

[0031] Fourth, the decorative surface layer and the snap-tooth base layer of this invention are produced and inspected independently before being combined, making the finished product yield easier to control than that of a one-piece molded product. The decorative surface layer has nine optional layer structures, and the snap-tooth base layer has five optional layer structures. By combining the two, forty-five product structures can be obtained. With various snap-tooth shapes, snap-tooth quantities and distribution methods, as well as different specifications and sizes, the product structures are extremely rich and can be customized according to customer needs, also possessing DIY attributes.

[0032] Fifth, the composite layer of the present invention can be supplemented with short-cut glass fibers, glass fiber layers can be set between layers, and a balancing layer can be composited on the back of the toothed base layer. The excellent low shrinkage and low expansion characteristics of glass fibers are used to control the product expansion value, and there are no obvious gaps at the splice after long-term use.

[0033] Sixth, the decorative surface layer of the present invention may optionally be provided with a barrier film with extremely low plasticizer content, which effectively blocks the migration of plasticizer in the composite base layer to the adhesive layer, ensuring the long-term bonding strength of the adhesive layer; the barrier film also allows the product to use conventional PVC formulation systems containing plasticizers without increasing the formulation cost.

[0034] Seventh, after the installation and splicing of this invention, the interlocking joint of the interlocking teeth is covered by the decorative surface layer of the adjacent floor, so that no interlocking teeth or seams are visible from the surface, thus combining overall visual aesthetics and sealing performance. Attached Figure Description

[0035] Figure 1 This is a schematic diagram of the layer structure of the flooring of the present invention;

[0036] Figure 2This is a top view of the floorboards after misalignment and bonding according to the present invention;

[0037] Figure 3 Schematic diagram of various optional layer structures for decorative surface layers;

[0038] Figure 4 A schematic diagram showing various optional layer structures for the toothed base layer;

[0039] Figure 5 The diagram shows the shapes of the snap teeth (a, b, c, and d represent elliptical, circular, concave, and swallowtail shapes, respectively).

[0040] Figure 6 Schematic diagram of the misalignment fitting positioning fixture;

[0041] In the diagram: 1-Decorative surface layer; 2-Adhesive layer; 3-Interlocking base layer; 11-Surface UV layer; 12-Transparent wear-resistant layer; 13-Printed decorative layer; 14-Composite intermediate layer; 15-Composite base layer; 16-Fiberglass layer; 19-Homogeneous through-layer; 20-PVC woven material layer; 21-Wear-resistant impregnated paper layer; 22-Rigid board; 31-Concave and convex interlocking teeth; 32-L-shaped exposed overlapping edge; 33-Hidden interlocking teeth; 41-L-shaped positioning plate; 42-Backing block. Detailed Implementation

[0042] The present invention will be further described below with reference to the accompanying drawings and embodiments. It should be understood that the following embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit the scope of protection of the present invention.

[0043] Reference Figure 1 and Figure 2 The multi-structure quick-install and quick-remove floor with invisible interlocking teeth provided in this embodiment includes a decorative surface layer 1, an adhesive layer 2, and an interlocking tooth base layer 3. The decorative surface layer 1 and the interlocking tooth base layer 3 are both independently molded sheet semi-finished products, which are bonded together by the adhesive layer 2. The concave and convex interlocking teeth 31 are provided on the edge of the interlocking tooth base layer 3 and are obtained by punching or milling the interlocking tooth base layer 3. The decorative surface layer 1 is horizontally offset from the interlocking tooth base layer 3, so that the concave and convex interlocking teeth 31 on the two adjacent sides of the interlocking tooth base layer 3 are covered under the decorative surface layer 1 to form hidden interlocking teeth 33. The concave and convex interlocking teeth 31 on the other two sides opposite to the two adjacent sides extend beyond the edge of the decorative surface layer 1, and together with the edge of the decorative surface layer 1, they form an L-shaped exposed overlapping edge 32.

[0044] Reference Figure 3 The decorative surface layer 1 has the following nine optional layer structures: Decorative surface layer structure one: from top to bottom, it includes a surface UV layer 11, a transparent wear-resistant layer 12, a printed decorative layer 13, a composite intermediate layer 14, and a composite base layer 15.

[0045] Decorative surface layer structure two: from top to bottom, it includes a surface UV layer 11, a transparent wear-resistant layer 12, a printed decorative layer 13, a composite intermediate layer 14, a fiberglass layer 16, and a composite base layer 15;

[0046] Decorative surface layer structure three: from top to bottom, it includes a surface UV layer 11 and a homogeneous through layer 19;

[0047] Decorative surface layer structure four: from top to bottom, it includes a surface UV layer 11, a homogeneous through layer 19, and a composite base layer 15;

[0048] Decorative surface layer structure five: from top to bottom, it includes a surface UV layer 11, a homogeneous through layer 19, a fiberglass layer 16, and a composite base layer 15;

[0049] Decorative surface layer structure six: from top to bottom, it includes a surface UV layer 11, a PVC woven material layer 20, and a composite base layer 15;

[0050] Decorative surface layer structure seven: from top to bottom, it includes wear-resistant impregnated paper layer 21, printed decorative layer 13, composite intermediate layer 14 and composite base layer 15;

[0051] Decorative surface layer structure eight: from top to bottom, it includes a wear-resistant impregnated paper layer 21, printed decorative layer 13, composite intermediate layer 14, glass fiber layer 16 and composite base layer 15;

[0052] Decorative surface structure nine: A sound-absorbing layer is glued to the back of any one of the above decorative surface structures one to eight, that is, from top to bottom, it includes any one of the above structures (1) to (8) and a sound-absorbing layer.

[0053] The surface UV layer 11 is a surface-hardened coating formed by UV coating film coating and tempering; the transparent wear-resistant layer 12 can be made of PVC, TPU, PP or PET; the printed decorative layer 13 can be a printed decorative film with adhesive on the surface; the fiberglass layer 16 is a mesh-like fiberglass or resin-impregnated fiberglass cloth; the homogeneous through-layer 19 is an elastic sheet material with uniform color and pattern inside and out; the PVC woven material layer 20 is a PVC sheet material retaining the woven texture; and the wear-resistant impregnated paper layer 21 is decorative paper impregnated with wear-resistant resin. Short-cut fiberglass can be dispersed in both the composite intermediate layer 14 and the composite base layer 15. To alleviate plasticizer precipitation, a barrier film can be added to the bottom layer of the decorative surface layer structure one, two, four to eight. The barrier film is a PVC film with a very low plasticizer content (i.e., a polyvinyl chloride film with a plasticizer content far lower than that of the composite base layer), with a thickness of 0.02mm to 1.0mm, used to prevent the plasticizer in the composite base layer 15 from migrating upwards.

[0054] In the above structures, the total thickness of decorative surface layer 1 can be 1.0mm to 6mm, and the total thickness of decorative surface layer structures four and five can be 1.5mm to 10mm; the thickness of PVC woven material layer 20 in decorative surface layer structure six can be 1.0mm to 4mm, and the total thickness of its structure can be 1.5mm to 6mm. The material of the sound-absorbing layer can be cross-linked polyethylene foam (IXPE), foamed EVA, foamed PVC, non-woven fabric, flocked fabric, or cork, etc., with a thickness of 0.10mm to 4.0mm. The length of chopped glass fiber is 0.05mm to 20mm, and the weight percentage is 1% to 15%; the basis weight of glass fiber layer 16 is 20g / m² to 500g / m².

[0055] Reference Figure 4 The toothed base layer 3 has the following five optional layer structures:

[0056] Toothed base structure one: a single-layer structure composed of composite base material layer 15;

[0057] The second type of toothed base structure consists of a composite intermediate layer 14 and a composite base layer 15, from top to bottom.

[0058] The third type of interlocking base structure consists of, from top to bottom, a composite intermediate layer 14, a fiberglass layer 16, and a composite base layer 15.

[0059] The fourth type of interlocking base structure consists of rigid boards 22, which are selected from rigid PVC extruded boards, extruded PVC foamed boards, thick non-woven fabrics, plastic foam boards (EVA, PP, etc.), wood boards, gypsum boards, MDF boards, or rigid foamed materials (rigid polyurethane foam, polyimide (PI) foam, etc.). The concave and convex interlocking teeth 31 on the edges are formed by punching and cutting the thick non-woven fabric with a special shape die, and the remaining rigid boards are formed by precision milling.

[0060] Five-layer buckle base structure: A sound-absorbing layer is bonded to the back of any one of the buckle base structures one to four above via an adhesive layer. The thickness of buckle base 3 is 1.0mm to 6.0mm; the surface of the semi-finished products of buckle base structures one to three is plain-textured to facilitate subsequent adhesive bonding, and the back has a textured surface; the extruded buckle base 3 can also have a balancing layer laminated on the back to balance product warpage, and the balancing layer is a substrate of the same material with less plasticizer.

[0061] Since the decorative surface layer 1 has nine optional layer structures and the buckle base layer 3 has five optional layer structures, the two can be combined in any way to form forty-five different product structures. With different buckle shapes, buckle numbers, buckle distribution methods and different specifications and sizes, an extremely rich product series can be formed, which can be customized according to customer needs and also have DIY attributes.

[0062] Reference Figure 5The convex and concave teeth 31 can be any of the following: dovetail-shaped teeth, oval teeth, circular teeth, or "U"-shaped teeth, or other irregularly shaped teeth, ensuring that the teeth interlock and mesh when the products are assembled. Each floorboard has 1 to 100 convex and concave teeth, and the size, shape, and distribution of the teeth can be adjusted according to actual requirements. The convex and concave teeth 31 interlock and lock together when pressed vertically, with moderate tightness and no need for hammering. The rounded corners at the root and corners prevent stress concentration and prevent breakage or disengagement at the root of the teeth. The beveled transition at the corners and the straight end sections ensure smooth connection and complete meshing of the teeth on all four sides.

[0063] This embodiment also provides a method for preparing the above-mentioned multi-structure quick-installation and quick-removal floor with invisible interlocking teeth, including steps S1 to S5.

[0064] S1. Preparation of the decorative surface layer semi-finished product. The composite intermediate layer 14 and composite base layer 15 are prepared by mixing, kneading (or screw extrusion), calendering, and sheeting PVC resin powder, plasticizer, calcium carbonate, stabilizer, and processing aids according to a certain formula ratio to prepare the composite intermediate layer and composite base layer of the required thickness, which can be 0.4mm to 6.0mm, and the density can be 0.6 to 3.5g / cm³. When containing chopped glass fiber, PVC resin powder, plasticizer, stabilizer, calcium carbonate, chopped glass fiber, and processing aids are prepared according to the formula ratio through the above process, with the chopped glass fiber content (by weight) accounting for 1% to 15%. The composite intermediate layer 14 and composite base layer 15 can be made of plastics other than PVC, such as PP, TPU, and PET. The PP composite intermediate and base layers are prepared by mixing 90%–99% PP particles, 0.1%–10% plasticizer, 0.1%–3% heat stabilizer, 0%–1% color powder, and calcium carbonate and magnesium hydroxide (or other flame retardants, with a mixing ratio between 0% and 100%) as fillers, followed by mixing, internal mixing, calendering, and sheeting processes. The TPU composite intermediate and base layers are prepared by mixing TPU granules (processing temperature 120℃–150℃), PVC resin powder (SG-5~...). The PET substrate is prepared by mixing SG-8 type PVC powder, calcium carbonate (100-800 mesh) with plasticizer DOTP, rare earth composite stabilizer, rosin, toughening agent ACR, CPE, color powder, etc. in a certain proportion. Among them, PVC powder accounts for 0-60%, TPU accounts for 6%-100%, DOTP accounts for 0-32%, stabilizer accounts for 0.1%-3%, rosin, ACR, CPE, and color powder each account for 0-1%, and stone powder accounts for 2-4 times the total amount of other raw materials. The PET substrate is prepared by heating PET resin to a molten state at high temperature and then extruding it into sheets through an extruder. The sheet thickness is controlled by adjusting the temperature, pressure, and speed of the extruder.

[0065] In S1, there are two ways to form the decorative surface layer semi-finished product.

[0066] Method 1 is production using a hot and cold oil press: Materials of equal size (such as a transparent wear-resistant layer 12, a printed decorative layer 13, a composite intermediate layer 14, and a composite base layer 15, and, if necessary, a fiberglass layer 16 or a barrier film 17) are laid out sequentially. A textured board with stone or wood grain patterns (customizable) is placed on the transparent layer, and a textured board is placed under the composite base layer. The process involves flat vulcanization hot pressing or multi-layer hot and cold lamination to produce a semi-finished product with an embossed surface and a textured back. The hot and cold pressing process is as follows: hot pressing temperature 100℃~160℃, hot pressing time 1000~5000s, hot pressing pressure 2MPa~20MPa; cold pressing temperature 0℃~45℃, cold pressing time 1000~5000s, cold pressing pressure 2MPa~20MPa.

[0067] Method two involves extrusion production: PVC resin powder, heat stabilizer, calcium carbonate (heavy calcium carbonate, light calcium carbonate), toughening agent (ACR, etc.), internal and external lubricants, and other processing aids are mixed. Short-cut glass fiber filaments with a length of 0.05mm to 20mm and a proportion of 0% to 30% can also be added. The mixture is extruded through a twin-screw extruder to produce a composite substrate layer. Then, a transparent wear-resistant layer 12, a printed decorative layer 13, and an adhesive barrier layer 17 are bonded together in one step using a 4-roll or 5-roll hot press (one roll has an embossed pattern, and the other has a base pattern). After this process, the transparent wear-resistant layer 12, the printed decorative layer 13, the substrate layer, and the adhesive barrier layer 17 are bonded together. The mixture is then traction-cooled and cut into semi-finished products. The hot roller temperature is set at 120℃ to 220℃. After molding, the mixture is left to stand for a period of time (≥2 hours) and then subjected to a surface UV coating and tempering process to form a surface UV layer 11. Finally, it is left to cure in a constant temperature chamber until the product performance is stable before proceeding to the next molding step to obtain the desired decorative surface layer semi-finished product.

[0068] S2. Preparation of the semi-finished product of the toothed base layer. Toothed base layer structure one to three: Composite intermediate material layer of the same size, or composite intermediate material layer, glass fiber layer and composite base material layer are laid in sequence and formed into a semi-finished product by flat vulcanization hot pressing or multi-layer hot and cold bonding machine. The hot and cold pressing process parameters are the same as those of S1 (hot pressing temperature 100℃~160℃, hot pressing time 1000~5000s, hot pressing pressure 2MPa~20MPa; cold pressing temperature 0℃~45℃, cold pressing time 1000~5000s, cold pressing pressure 2MPa~20MPa). After forming, it is placed for tempering (≥2h) and then cured in a constant temperature room.

[0069] The toothed base structure 1 to 3 can also be produced using an extruder: PVC resin powder, heat stabilizer, calcium carbonate (heavy calcium carbonate, light calcium carbonate), toughening agent (ACR, etc.), internal and external lubricants, etc. are mixed. Short glass fiber filaments with a length of 1mm to 6mm and a proportion of 0 to 10% can be added. Plasticizers can also be added to reduce the softness and hardness of the substrate. The mixture is extruded through a twin-screw extruder and then hot-pressed by 4 or 5 rollers (one side with flat embossing and the other side with a base pattern), followed by traction, cooling, and cutting. The hot roller temperature is set to 60℃ to 250℃, and the Shore hardness can be 40 to 95. To balance product warpage, a balancing layer 23 can be added to the back of the substrate layer (composite to the substrate before the hot pressing roller, and fused into a whole after being rolled by the heated roller). Foaming agents (white foam, yellow foam, etc.) and foaming aids can also be added to the formulation system to produce micro-foamed substrates or foamed substrates.

[0070] The fourth type of buckle base structure: Thick non-woven fabric is punched and formed into concave and convex buckles using a special shape punching die; rigid PVC extruded sheets, extruded PVC foamed sheets, plastic foamed boards, wood boards, gypsum boards, MDF, rigid foamed materials, etc., are precision machined and milled to form the shape of concave and convex buckles.

[0071] Five-stage toothed base structure: After any one of the above toothed base structures one to four has been left to cure sufficiently, a two-component adhesive or PUR adhesive is applied to the back of the semi-finished product by roller coating with a backing adhesive machine, and the sound-absorbing layer 18 is attached to it, so that the product and the sound-absorbing layer are completely bonded together.

[0072] S3. Punching and forming: The decorative surface layer semi-finished product and the tooth base plate are punched and formed according to preset dimensions. During punching, concave and convex teeth 31 are simultaneously formed on the edge of the tooth base plate. When the tooth base plate 3 is a hard plate, the concave and convex teeth 31 are machined on its edge by precision milling. The semi-finished product can be square or rectangular, with a width of 50mm to 2500mm and a length of 50mm to 2500mm. As long as the forming dimensions of the decorative surface layer semi-finished product are the same as the effective dimensions of the concave and convex teeth of the tooth base plate, the production of this invention can be realized.

[0073] Taking a 24"×24" (609.6mm) square size as an example: the decorative surface layer 1 can be a single sheet, or it can be composed of two 12"×24" sheets, four 12"×12" sheets, or a combination of various irregular sizes. It can also be a combination of solid-color strips of the same thickness used to fill in the gaps when one or two sides are less than 24". The buckle base layer 3 is a convex and concave irregular buckle product with an effective size of 24" on all four sides. The shape and number of the convex and concave irregular buckles can be of various forms, as long as they can be fastened when tapped up and down. Taking a 185mm×1200mm long strip size as another example: the decorative surface layer 1 can be a single sheet, or it can be a combination of two or more sizes. The buckle base layer 3 is a convex and concave buckle product with an effective area of ​​185mm×1200mm. It can have buckles on two sides or on all four sides.

[0074] S4. Backing Adhesive: After molding, apply backing adhesive to the back of decorative surface layer 1. The adhesive used for bonding the two layers can be environmentally friendly hot melt adhesive, PUR adhesive (polyurethane reactive adhesive), two-component adhesive, white glue, all-purpose adhesive, or other suitable adhesives. When using hot melt adhesive for bonding: Select a hot melt adhesive suitable for LVT flooring, set the working temperature of the hot melt adhesive machine to 150℃~250℃ for the heating oil, 140℃~220℃ for the coating steel roller, and 130℃~200℃ for the adhesive. After the adhesive is completely melted, has uniform fluidity, and is free of lumps and bubbles, evenly feed the back of decorative surface layer 1 into the coating roller and apply the hot melt adhesive to the back of the product. When using PUR adhesive for bonding: the heating plate temperature is 130℃~180℃, the coating steel roller temperature is 140℃~220℃, and the adhesive temperature is 100℃~150℃. After the adhesive has completely melted, has uniform fluidity, and is free of lumps and bubbles, it is roller-coated onto the back of decorative surface layer 1. When using two-component adhesive, white glue, or all-purpose adhesive for bonding: adjust the speed of each transmission component, stir the adhesive evenly according to the process requirements, pour it onto the opposing rotating adhesive coating rollers, and after the adhesive has uniform fluidity, evenly feed decorative surface layer 1, back side up, into the coating rollers for coating. The adhesive coating amount for all the above back-adhesive methods is controlled between 10g / m² and 500g / m².

[0075] S5, Misaligned Fitting: Refer to Figure 6 The decorative surface layer 1, after being coated with adhesive, is then staggered and bonded to the toothed base layer 3 using a positioning fixture. The positioning fixture includes an L-shaped positioning plate 41 and several support blocks 42. The specific bonding method is as follows: First, an L-shaped positioning plate is made. The two sides of the toothed base layer 3 are positioned against the inner edge of the L-shaped positioning plate 41. Four support blocks 42 are placed on the toothed base layer 3 to prevent misalignment during bonding. Then, the coated decorative surface layer 1 is positioned according to the support blocks 42 and bonded tightly to the toothed base layer 3. After bonding, it is pressed firmly to ensure the adhesive fully adheres to the decorative surface layer 1 and the toothed base layer 3. After bonding, the protruding and concave teeth 31 on both sides adjacent to the L-shaped positioning plate 41 are exposed below the decorative surface layer 1, forming L-shaped exposed overlapping edges 32. The protruding and concave teeth 31 on the other two sides are hidden within the edges of the decorative surface layer 1, forming hidden teeth 33. A finished piece is then complete. The preset misalignment is: 0mm in the horizontal direction to 1 / 2 of the product length, and 0mm in the vertical direction to 1 / 2 of the product width. That is, the decorative surface layer 1 and the buckle base layer 3 can be nearly aligned or offset by up to half a product size.

[0076] Furthermore, after the punching process, the finished product can be beveled and chamfered to improve the paving effect; the toothed base layer 3 can be made with different textures to suit different paving occasions.

[0077] Because the decorative surface layer 1 is a full-width sheet of adhesive backing that is then staggered and bonded to the interlocking base layer 3, a portion of the adhesive layer remains exposed at the recessed area of ​​the L-shaped exposed overlap edge 32. This residual adhesive layer forms an auxiliary bonding layer used to bond adjacent floorboards during installation. Since the adhesive layer is located in the middle layer of the product structure, the exposed adhesive during packaging will not affect other products; and during installation, this residual adhesive precisely helps to bond and fix the interlocking teeth of two adjacent floorboards, preventing edge lifting. This production method also eliminates the need for a transition adhesive release paper.

[0078] This embodiment also provides a method for installing multi-structure quick-install and quick-remove flooring with invisible interlocking teeth: the first flooring is laid flat on the ground to be installed; the second flooring is taken and its exposed interlocking teeth 31 are aligned with the corresponding interlocking teeth 31 of the first flooring in the horizontal plane; then it is pressed down vertically so that the protrusions and concaves of the two floorings interlock, thereby locking the two floorings in the horizontal direction; the decorative surface layer 1 of the second flooring covers the interlocking interlocking teeth 31 of the two floorings, so that the joint is not visible from above; at the same time, the adhesive layer remaining at the concave of the L-shaped exposed overlapping edge 32 of the first flooring bonds and fixes the interlocking teeth of the two adjacent floorings, suppressing the edge from lifting due to changes in ambient temperature and humidity.

[0079] There are several ways to stagger adjacent floorboards during installation: the upper layer can be laid right next to the lower layer at the interlocking teeth, the upper and lower layers can be partially staggered at the interlocking teeth, or the upper layer with decorative products can be laid with edge strips to fill in the gaps. All of these methods can achieve a glue-free, hammer-free, and invisible splicing installation effect.

[0080] Example 1: A multi-structure quick-install and quick-remove floor with invisible interlocking teeth, employing a combination of decorative surface layer structure two and interlocking tooth base layer structure three. The decorative surface layer 1, from top to bottom, consists of a surface UV layer 11, a transparent wear-resistant layer 12 (PVC material, 0.3mm thick), a printed decorative layer 13, a composite intermediate layer 14 (PVC material, containing 1% chopped fiberglass, 1.6mm thick), a fiberglass layer 16 (impregnated fiberglass cloth, 100g / m²), and a composite base layer 15 (PVC material, containing 5% chopped fiberglass, 1.5mm thick), with a total thickness of approximately 3.8mm. A barrier film 17 (0.05mm thick) is added to the bottom surface of the composite base layer 15. The interlocking tooth base layer 3, from top to bottom, consists of a composite intermediate layer 14 (1.5mm thick), a fiberglass layer 16 (100g / m²), and a composite base layer 15 (1.5mm thick), with a total thickness of approximately 3.1mm. During preparation, each layer is laid out sequentially and then pressed into shape using a hot and cold oil press. The hot pressing temperature is 140℃, the hot pressing time is 3000s, and the hot pressing pressure is 10MPa. The cold pressing temperature is 25℃, the cold pressing time is 3000s, and the cold pressing pressure is 10MPa. After standing for 2 hours, UV coating and tempering are performed, followed by static curing in a constant temperature chamber. The two semi-finished layers are punched into 609.6mm×609.6mm dimensions, and dovetail-shaped concave and convex teeth 31 are simultaneously punched on the four sides of the toothed base layer 3. Subsequently, decorative... The back of the surface layer 1 is coated with hot melt adhesive (heating oil temperature 200℃, coating steel roller temperature 180℃, adhesive temperature 160℃, coating amount 120g / m²); finally, the L-shaped positioning plate 41 is used in conjunction with four backing blocks 42 for positioning, and the decorative surface layer 1 and the buckle base layer 3 are staggered and bonded (the horizontal and vertical stagger is 20mm, which is approximately equal to the height of the buckle protrusion, so that the buckle on the exposed side is fully exposed) and pressed tightly, resulting in a finished product where the buckles on the two adjacent sides are hidden and the other two sides form an L-shaped exposed overlapping edge 32.

[0081] Example 2: A multi-structure quick-installation and quick-removal floor with concealed interlocking teeth, employing a combination of decorative surface layer structure five and interlocking tooth base layer structure four. The decorative surface layer 1, from top to bottom, consists of a surface UV layer 11, a homogeneous core layer 19 (2.0mm thick), a fiberglass layer 16 (mesh fiberglass, 150g / m²), and a composite base layer 15 (containing 3% chopped fiberglass, 1.2mm thick), with a total thickness of approximately 4.2mm. The interlocking tooth base layer 3 is made of rigid PVC extruded board 22 (4.0mm thick), with four sides precisely milled into concave-convex interlocking teeth 31 (4 teeth per side, 25mm high). Its bottom surface is bonded with a cork sound-absorbing layer 18 (1.5mm thick) using PUR adhesive. The floor is a 185mm × 1200mm long strip, with interlocking teeth on both sides of the interlocking tooth base layer 3. The adhesive backing uses PUR glue (heated pressure plate temperature 160℃, coating steel roller temperature 180℃, glue temperature 130℃, coating amount 150g / m²). After staggered bonding, one side of the finished product has hidden teeth, while the other side is exposed. This product can be laid on the living room floor without applying glue or hammering, providing a quiet feel underfoot, and can be repeatedly disassembled and reused.

[0082] Example 3: A multi-structure quick-install and quick-remove floor with invisible interlocking teeth, employing a combination of decorative surface layer structure nine and interlocking tooth base layer structure one. Decorative surface layer structure nine is based on decorative surface layer structure one, with an IXPE sound-absorbing layer 18 (1.0mm thick) applied to its back using a two-component adhesive roller. Specifically, decorative surface layer 1, from top to bottom, consists of a surface UV layer 11, a transparent wear-resistant layer 12 (0.5mm thick), a printed decorative layer 13, a composite intermediate layer 14 (1.5mm thick), a composite base layer 15 (1.2mm thick), and the sound-absorbing layer 18 adhered to its back, for a total thickness of approximately 4.8mm. The interlocking tooth base layer 3 is a single-layer structure of composite base layer 15 (3.0mm thick). The dimensions are a 450mm × 450mm square, with elliptical concave-convex interlocking teeth 31 punched on all four sides (6 teeth on each side). The two-component adhesive backing has a coating amount of 200g / m². After staggered bonding, the interlocking teeth on the two adjacent sides of the interlocking base layer are hidden, while the other two sides are exposed. The sound-absorbing layer 18 is applied to the bottom surface of the adhesive layer and the top surface of the interlocking base layer 3 after the backing adhesive in step S4. It also has the function of reducing noise during installation.

[0083] The flooring of this invention requires no glue or hammering during installation, produces little noise, and generates no debris; it is easy to disassemble, can be disassembled without damage, and can be reinstalled and reused; the adhesive layer is located inside the product structure, and there is no glue or release paper on the back of the product, avoiding problems such as glue failure caused by plasticizer migration, sticky hands during construction, and waste of release paper.

[0084] The above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A multi-structure quick-installation and quick-removal floor with concealed interlocking teeth, characterized in that: It includes a decorative surface layer (1), a toothed base layer (3), and an adhesive layer (2); the decorative surface layer (1) is an independently formed sheet, which from top to bottom includes at least a transparent wear-resistant layer (12), a printed decorative layer (13), and a composite base layer (15); the toothed base layer (3) is an independently formed sheet, located below the decorative surface layer (1), and the edge of the toothed base layer (3) is provided with concave and convex teeth (31), which are obtained by punching or milling the toothed base layer (3); the adhesive layer (2) is provided on... Between the decorative surface layer (1) and the buckle base layer (3), the decorative surface layer (1) and the buckle base layer (3) are combined into one. The decorative surface layer (1) is staggered in the horizontal direction relative to the buckle base layer (3), so that the concave and convex buckles (31) on the two adjacent sides of the buckle base layer (3) are covered under the decorative surface layer (1) to form hidden buckles (33). The concave and convex buckles (31) on the other two sides opposite to the two adjacent sides extend beyond the edge of the decorative surface layer (1) to form an L-shaped exposed overlapping edge (32).

2. The multi-structure quick-installation and quick-removal floor with invisible interlocking teeth according to claim 1, characterized in that, The decorative surface layer (1) further includes a surface UV layer (11) disposed on the upper surface of the transparent wear-resistant layer (12), and / or a composite intermediate layer (14) disposed between the printed decorative layer (13) and the composite base layer (15).

3. The multi-structure quick-install and quick-remove flooring with concealed interlocking teeth according to claim 2, characterized in that, Short-cut glass fibers are dispersedly added to the composite intermediate layer (14) and / or the composite base layer (15), the length of the short-cut glass fibers being 0.05mm-20mm and the weight percentage being 1%-15%; or, the decorative surface layer (1) further includes a glass fiber layer (16), the glass fiber layer (16) being a mesh-like glass fiber or impregnated glass fiber cloth, with a basis weight of 20g / m²-500g / m², and is disposed between the composite intermediate layer (14) and the composite base layer (15).

4. The multi-structure quick-installation and quick-removal floor with invisible interlocking teeth according to claim 1, characterized in that, The transparent wear-resistant layer (12) and the printed decorative layer (13) are replaced by any of the following structures: a homogeneous through layer (19); a PVC woven material layer (20); or a combination of a wear-resistant impregnated paper layer (21) and printed decorative layer (13); the floor has a width of 50mm-2500mm and a length of 50mm-2500mm.

5. The multi-structure quick-installation and quick-removal floor with invisible interlocking teeth according to claim 1, characterized in that, A barrier film is also provided between the decorative surface layer (1) and the adhesive layer (2). The barrier film is a polyvinyl chloride film containing plasticizer with a thickness of 0.02mm-1.0mm, which is used to prevent the plasticizer in the composite base layer (15) from migrating to the adhesive layer (2).

6. The multi-structure quick-install and quick-remove flooring with concealed interlocking teeth according to claim 1, characterized in that, The concave and convex buckles (31) are any one of elliptical buckles, circular buckles, concave buckles, or swallowtail buckles; the number of concave and convex buckles (31) on each floor is 1-100, the biting angle of the swallowtail buckles is 45°-65°, and the radius of the root transition rounded corner is 2mm-5mm.

7. The multi-structure quick-installation and quick-removal floor with invisible interlocking teeth according to claim 1, characterized in that, The adhesive layer (2) is selected from hot melt adhesive layer, polyurethane reactive adhesive layer, two-component adhesive layer, white latex layer or universal adhesive layer, and the coating amount is 10g / m²-500g / m²; the adhesive layer remaining at the recess of the protruding teeth (31) extending beyond the edge of the decorative surface layer (1) constitutes the auxiliary adhesive part for bonding adjacent floorboards during installation.

8. The multi-structure quick-install and quick-remove floor with invisible interlocking teeth according to claim 1, characterized in that, It also includes a sound-absorbing layer, which is attached to the top surface of the adhesive layer (2) or the bottom surface of the tooth base layer (3). The material of the sound-absorbing layer is cross-linked polyethylene foam, foamed EVA, foamed PVC, non-woven fabric, flocked fabric or cork, and the thickness is 0.10mm-4.0mm.

9. The multi-structure quick-installation and quick-removal floor with invisible interlocking teeth according to claim 1, characterized in that, The toothed base layer (3) is selected from any of the following structures: a single-layer structure composed of a composite base layer (15); a composite structure composed of a composite intermediate layer (14) and a composite base layer (15); a composite structure composed of a composite intermediate layer (14), a glass fiber layer (16) and a composite base layer (15); or a structure obtained by milling a rigid board (22), wherein the rigid board (22) is selected from rigid PVC extruded board, extruded PVC foamed board, thick non-woven fabric, plastic foam board, wood board, gypsum board, MDF or rigid foamed material board; the thickness of the toothed base layer is 1.0mm-6.0mm.

10. A method for preparing a multi-structure quick-install and quick-remove floor with invisible interlocking teeth as described in any one of claims 1 to 9, characterized in that, Includes the following steps: S1. Preparation of decorative surface layer (1) semi-finished product: The transparent wear-resistant layer (12), the printed decorative layer (13), and the composite base layer (15) are stacked in sequence and formed by cold and hot pressing or extrusion to form a decorative surface layer (1) semi-finished product. After forming, UV coating tempering treatment and constant temperature curing treatment are carried out in sequence. S2. Preparation of the toothed base layer (3) semi-finished product: The raw materials are mixed, intensively mixed and calendered into sheets according to the proportion, or extruded to obtain the toothed base layer (3) sheet; S3, punching and forming: the semi-finished decorative surface layer (1) and the tooth base layer (3) are punched and formed according to the preset size. During punching, the concave and convex teeth (31) are formed simultaneously on the edge of the tooth base layer (3). When the tooth base layer (3) is a hard plate, the concave and convex teeth (31) are processed on its edge by precision milling. S4, Adhesive backing: Apply adhesive to the back of the decorative surface layer (3), with a coating amount of 10g / m²-500g / m²; S5, staggered bonding: The decorative surface layer (1) after applying glue is overlapped and pressed together with the toothed base layer (3) according to a preset staggered amount, so that the concave and convex teeth (31) on the two adjacent sides of the toothed base layer (3) are covered under the decorative surface layer (1) to form hidden teeth (33). The concave and convex teeth (31) on the other two sides opposite to the two adjacent sides extend beyond the edge of the decorative surface layer (1) and together with the edge of the decorative surface layer (1) form an L-shaped exposed overlapping edge (32) to obtain the multi-structure quick-installation and quick-removal floor with hidden teeth.

11. The preparation method according to claim 10, characterized in that, In step S5, a positioning fixture is used for misaligned fitting: the positioning fixture includes an L-shaped positioning plate (41) and several backing blocks (42); the adjacent two sides of the tooth base layer (3) are positioned against the inner edge of the L-shaped positioning plate (41), the backing blocks (42) are placed on the tooth base layer (3), and the glued decorative surface layer (1) is then pressed against the backing blocks (42) and attached to the tooth base layer (3); the preset misalignment amount is: 0mm in the horizontal direction to half the product length, and 0mm in the vertical direction to half the product width.

12. The preparation method according to claim 10, characterized in that, In step S4, when hot melt adhesive is used, the heating oil temperature of the hot melt adhesive machine is set to 150℃-250℃, the coating steel roller temperature is set to 140℃-220℃, and the adhesive temperature is 130℃-200℃; when polyurethane reactive adhesive is used, the heating platen temperature is set to 130℃-180℃, the coating steel roller temperature is set to 140℃-220℃, and the adhesive temperature is 100℃-150℃.

13. A method for installing flooring, using the multi-structure quick-install and quick-remove flooring with concealed interlocking teeth as described in any one of claims 1 to 9, characterized in that... include: Lay the first floorboard flat on the surface to be paved; Take the second floorboard and align its exposed interlocking teeth (31) with the corresponding interlocking teeth (31) of the first floorboard in the horizontal plane. Then press it down vertically so that the protruding teeth and the interlocking teeth of the two floorboards interlock with each other, thereby locking the two floorboards in the horizontal direction. The decorative surface layer (1) of the second floorboard covers the interlocking interlocking teeth (31) of the two floorboards, so that the splice is not visible from above. At the same time, the adhesive layer remaining at the L-shaped exposed overlapping edge (32) will bond and fix the interlocking teeth of the two adjacent floorboards.

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