Stone-plastic hot-pressed flooring and its manufacturing process

Abstract

Stone-plastic hot-pressed flooring, comprising: a stone-plastic base material part, comprising a middle material layer, a stone-plastic substrate layer and a bottom material layer, arranged side by side; a colored film layer located on one side of an upper surface of the stone-plastic base material part; a first wear-resistant layer located on one side of an upper surface of the colored film layer, and a second wear-resistant layer located on one side of a lower surface of the stone-plastic base material part; wherein both the middle material layer and the bottom material layer are composed of polyvinyl chloride, plasticizer, stabilizer, carbon black and stone flour, characterized in that the weight fractions of the polyvinyl chloride, plasticizer, stabilizer, carbon black and stone flour in the bottom material layer are 100:(25-35):(2-5):(0.5-2):(100-200).

Description

Background of the invention; Field of the invention

[0001] This invention relates to a stone-plastic hot-pressed floor covering and a manufacturing process thereof, and in particular to a field of building materials. Description of the state of the art

[0002] Stone-effect plastic flooring, also known as stone-effect plastic floor tile, is a high-quality, innovative flooring material researched and developed using cutting-edge technology. Natural marble powder is used to form a solid base layer with a high density and fibrous network structure, and the surface is coated with a wear-resistant layer of extremely durable polymer PVC, which undergoes hundreds of processes.

[0003] Compared to other flooring materials, stone-effect laminate flooring offers the following advantages: 1) Green and environmentally friendly: The main raw material used in the production of stone-effect laminate flooring is natural stone flour, making it a new, green, and environmentally friendly flooring material. 2) The stone-effect laminate is strong and will not warp or bend. 3) Extremely wear-resistant: It features a special, transparent, wear-resistant layer processed using state-of-the-art technology, and the wear resistance can reach up to 300,000 revolutions per minute. Conventional flooring materials, which are relatively wear-resistant, have a wear resistance of only 13,000 revolutions per minute, and even well-laminated flooring only 20,000 revolutions per minute. The extremely wear-resistant layer with its specially treated surface fully guarantees the excellent wear resistance of this flooring material.Under normal circumstances, the wear-resistant layer of the stone-effect laminate flooring can last from 5 to 10 years, depending on its thickness. The thickness and quality of the wear-resistant layer directly determine the lifespan of the stone-effect laminate flooring. Standard test results show that a 0.55 mm thick wear-resistant laminate flooring can be used for more than 5 years under normal circumstances, while a 0.7 mm thick wear-resistant laminate flooring can be used for more than 10 years, making it extremely wear-resistant. Due to its extremely wear-resistant properties, stone-effect laminate flooring is becoming increasingly popular in hospitals, schools, public buildings, shopping malls, supermarkets, and other high-traffic areas.4) High elasticity and extreme impact resistance: The elasticity of the stone-effect vinyl flooring is excellent, as its relatively soft texture allows it to rebound well when struck by heavy objects. Its feel underfoot is comfortable and is often described as "soft gold." Simultaneously, the vinyl flooring possesses high impact resistance, exhibiting strong elastic recovery from impacts caused by heavy objects and preventing damage. This excellent vinyl flooring minimizes the impact on the human body, distributing the impact across the foot. Recent research shows that in areas with high foot traffic, the installation of this excellent vinyl flooring reduces the rate of falls and injuries among personnel by approximately 70% compared to other flooring types.5) Extremely slip-resistant: The wear-resistant layer of the stone-effect laminate flooring surface has a special slip-resistant property. Compared to ordinary flooring materials, the surface feels harder when wet, making it less likely to slip. In other words, the more water it gets, the harder it becomes. 6) Fire-resistant: The fire protection rating of qualified, high-quality stone-effect laminate flooring can reach level B1. Level B1 means that the fire protection performance is very good and only slightly lower than that of natural stone.

[0004] The existing stone-plastic hot-pressed floor covering has deficiencies such as a high damping value, relatively high density and a poor feel underfoot. Brief summary of the invention: Technical problems to be solved in stone-plastic hot-pressed flooring

[0005] The aim of the present invention is to provide a stone-plastic hot-pressed floor covering that overcomes the shortcomings of a relatively high density, a poor feel underfoot and a high damping value in existing stone-plastic hot-pressed floor coverings. Technical solution

[0006] To solve the aforementioned technical problem, the present invention provides a stone-plastic hot-pressed floor covering comprising a stone-plastic base material part, comprising a middle material layer, a stone-plastic substrate layer, and a bottom material layer arranged side by side; a colored film layer located on one side of an upper surface of the stone-plastic base material part; a first wear-resistant layer located on one side of an upper surface of the colored film layer; and a second wear-resistant layer located on one side of a lower surface of the stone-plastic base material part; wherein the middle material layer and the bottom material layer are mainly composed of polyvinyl chloride, plasticizer, stabilizer, carbon black, and stone flour.

[0007] In this invention, the stress equilibrium of the stone-plastic substrate layer is achieved by symmetrically arranging the middle material layer and the bottom material layer relative to the stone-plastic substrate layer. The middle material layer and the bottom material layer are primarily composed of polyvinyl chloride, plasticizers, stabilizers, carbon black, and stone flour. Furthermore, the first and second wear-resistant layers are symmetrically arranged. While ensuring the product's strength, the product's density is reduced, the walking feel is improved, and the damping value is reduced.

[0008] Optionally, the thicknesses of both the first wear-resistant layer and the second wear-resistant layer are in the range of 0.07-0.7 mm, the thickness of the color foil layer is in the range of 0.07-0.7 mm, the thickness of the stone plastic substrate layer is in the range of 1.5-4.0 mm, the thickness of the middle material layer is in the range of 1.8-2.0 mm and the thickness of the bottom material layer is in the range of 1.6-1.8 mm.

[0009] Optionally, both densities of the first wear-resistant layer and the second wear-resistant layer are in the range of 1.10-1.40 g / cm³. 3 .

[0010] Optionally, the density of the stone-plastic substrate layer is in the range of 1.8-2.1 g / cm³. 3 , the density of the middle material layer is in the range of 1.6-2.0 g / cm³ 3 and the density of the soil material layer is in the range of 1.6-2.0 g / cm³ 3 .

[0011] Optionally, the weight proportions of polyvinyl chloride, plasticizer, stabilizer, carbon black and stone flour in the middle material layer are 100:(35-40):(2-5):(0.5-2):(400-500).

[0012] Optionally, the weight proportions of polyvinyl chloride, plasticizer, stabilizer, carbon black and stone flour in the soil material layer are 100:(25-35):(2-5):(0.5-2):(100-200).

[0013] Optionally, the plasticizer is made from dioctyl terephthalate.

[0014] Optionally, the shrinkage rate of the stone-plastic hot-pressed flooring is in the range of 0.60%-0.90%.

[0015] Optionally, the expansion rate of the stone-plastic hot-pressed flooring is in the range of 0.10%-0.15%.

[0016] Optionally, the sound damping value of the stone-plastic hot-pressed flooring is in the range of 65-75 decibels.

[0017] The present invention further provides a manufacturing process for the aforementioned stone-plastic hot-pressed floor covering, comprising the following steps: Adding and mixing raw materials of the soil material layer according to the above-mentioned component to obtain a soil material layer intermediate product, and subsequently internally mixing and calendering the soil material layer intermediate product to obtain a soil material layer web; Adding and mixing raw materials of a middle material layer according to the above-mentioned component to obtain a middle material layer intermediate product, and subsequently internally mixing and calendering the middle material layer intermediate product to obtain a middle material layer web; Mixing, internal mixing and calendering of raw materials of the stone-plastic substrate layer to obtain a stone-plastic substrate layer sheet, and successive arrangement of a first wear-resistant layer film, a color film, the middle material layer film, the stone plastic substrate layer film, the base material layer film and a second wear-resistant layer film, and then carrying out a hot pressing process to obtain a finished product.

[0018] Optionally, in the hot pressing process, a pressure is regulated in a range of 3-6 MPa, a temperature is regulated in a range of 125-145 °C, and a hot pressing time is regulated in a range of 1500-2100s.

[0019] Optionally, the manufacturing process for the hot-pressed stone-plastic flooring includes a further cold-pressing process. The cold-pressing process is carried out after the hot-pressing process and comprises a first and a second cold-pressing process.

[0020] In the first cold pressing process, a pressure is regulated in a range of 5-8 MPa, a temperature is regulated in a range of 80-145 °C and a cold pressing time is regulated in a range of 600-800s.

[0021] Optionally, in the second cold pressing process, a pressure is regulated in a range of 8-15 MPa, a temperature is regulated in a range of 23-80 °C, and a cold pressing time is regulated in a range of 800-1000s.

[0022] Optionally, a further cutting process is provided after calendering the soil material layer intermediate product or the middle material layer intermediate product or the stone plastic substrate layer. Positive effects

[0023] The present invention provides a stone-plastic hot-pressed floor covering with the following advantages:

[0024] In this invention, by increasing the middle material layer and the base material layer and regulating the weight ratio of the middle material layer and the base material layer, the tensile strength of the stone-plastic hot-pressed floor covering is increased, while at the same time the density and hardness of the product are reduced, and the reduction in the hardness of the product improves the feel underfoot. Detailed description of the invention

[0025] A particular embodiment of the present invention is described in more detail below in combination with other embodiments. The following embodiments are used to illustrate the present invention but are not intended to limit its scope.

[0026] All “one” in the present invention shall be understood to mean “at least one” or “one or two or more”.

[0027] The present invention provides a stone-plastic hot-pressed floor covering comprising a stone-plastic base material part, which includes a middle material layer, a stone-plastic substrate layer, and a bottom material layer arranged side by side; a colored film layer located on one side of an upper surface of the stone-plastic base material part; a first wear-resistant layer located on one side of an upper surface of the colored film layer; and a second wear-resistant layer located on one side of a lower surface of the stone-plastic base material part; and wherein the middle material layer and the bottom material layer are mainly composed of polyvinyl chloride, plasticizer, stabilizer, carbon black, and stone flour.

[0028] The thickness of both the first wear-resistant layer and the second wear-resistant layer is in the range of 0.07-0.7 mm, and the thickness of the color foil layer is in the range of 0.07-0.7 mm; and the thickness of the stone plastic substrate layer is in the range of 1.5-4.0 mm, the thickness of the middle material layer is in the range of 1.8-2.0 mm, and the thickness of the bottom material layer is in the range of 1.6-1.8 mm.

[0029] The densities of the first wear-resistant layer and the second wear-resistant layer are in the range of 1.10–1.40 g / cm³. 3 .

[0030] The density of the stone-plastic substrate layer is in the range of 1.8-2.1 g / cm³. 3 , the density of the middle material layer is in the range of 1.6-2.0 g / cm³ 3 and the density of the soil material layer is in the range of 1.6-2.0 g / cm³ 3 .

[0031] The weight proportions of polyvinyl chloride, plasticizer, stabilizer, carbon black and stone flour in the middle material layer are 100:(35-40):(2-5):(0.5-2):(400-500).

[0032] The weight proportions of polyvinyl chloride, plasticizer, stabilizer, carbon black and stone flour in the soil material layer are 100:(25-35):(2-5):(0.5-2):(100-200).

[0033] The plasticizer is made from dioctyl terephthalate.

[0034] The shrinkage rate of the stone-plastic hot-pressed flooring is in the range of 0.60%-0.90%.

[0035] The expansion rate of the stone-plastic hot-pressed flooring is in the range of 0.10%-0.15%.

[0036] The sound damping value of the stone-plastic hot-pressed flooring is in the range of 65-75 decibels.

[0037] The present invention further provides a manufacturing process for the aforementioned stone-plastic hot-pressed floor covering, comprising the following steps: Adding and mixing raw materials of the soil material layer according to the above-mentioned formula ratio to obtain a soil material layer intermediate product, and subsequently internally mixing and calendering the soil material layer intermediate product to obtain a soil material layer sheet; Adding and mixing raw materials of the middle material layer according to the above-mentioned formula ratio to obtain a middle material layer intermediate product, and subsequently internally mixing and calendering the middle material layer intermediate product to obtain a middle material layer web; Mixing, internal mixing and calendering of raw materials of the stone-plastic substrate layer to obtain a stone-plastic base material sheet, and successive arrangement of a first wear-resistant layer film, a color film, the middle material layer film, the stone plastic base film, the bottom material layer film and a second wear-resistant layer film, and then carrying out a hot pressing process to obtain a finished product.

[0038] In the hot pressing process, a pressure is regulated in a range of 3-6 MPa, a temperature is regulated in a range of 125-145 °C and a hot pressing time is regulated in a range of 1500-2100s.

[0039] The manufacturing process for the hot-pressed stone-plastic flooring also includes a cold-pressing process. The cold-pressing process is carried out after the hot-pressing process and comprises a first and a second cold-pressing process.

[0040] In the first cold pressing process, a pressure is regulated in a range of 5-8 MPa, a temperature is regulated in a range of 80-145 °C and a cold pressing time is regulated in a range of 600-800s.

[0041] In the second cold pressing process, a pressure is regulated in a range of 8-15 MPa, a temperature is regulated in a range of 23-80 °C and a cold pressing time is regulated in a range of 800-1000s.

[0042] Furthermore, a cutting process is provided after calendering the soil material layer intermediate product or the middle material layer intermediate product or the stone plastic substrate layer.

[0043] The formula of the stone-plastic substrate layer of the present embodiment is: name Quantity (kg) PVC-SG5 50 Stone flour at 400 mesh 110 stabilizer 6 Stearic acid 0,7 PE wax 0,6 ACR 4 CPE (chlorinated polyethylene) 4

[0044] ACR is a group of impact modifiers.

[0045] A specific description is provided by the following embodiments. Design One: A stone-plastic hot-pressed floor covering comprises a stone-plastic base material component, and the stone-plastic base material component comprises a middle material layer, a stone-plastic substrate layer, and a floor material layer, arranged side by side; a color foil layer located on one side of an upper surface of the stone-plastic base material component; a first wear-resistant layer located on one side of an upper surface of the colored film layer; and a second wear-resistant layer located on one side of a lower surface of the stone plastic base material part; and wherein the middle material layer and the bottom material layer are mainly composed of polyvinyl chloride, dioctyl terephthalate, stabilizer, carbon black and stone flour.

[0046] The thicknesses of the first wear-resistant layer and the second wear-resistant layer are 0.07 mm, and the thickness of the color foil layer is 0.07 mm; and the thickness of the stone plastic substrate layer is 1.5 mm, the thickness of the middle material layer is 1.8 mm, and the thickness of the bottom material layer is 1.6 mm.

[0047] The densities of the first wear-resistant layer and the second wear-resistant layer are 1.10 g / cm³. 3 The density of the stone-plastic substrate layer is 1.8 g / cm³. 3 , the density of the middle material layer is 1.6 g / cm³ 3 and the density of the soil material layer is 1.6 g / cm³ 3 .

[0048] In the middle layer of material, the weight proportions of polyvinyl chloride, plasticizer, stabilizer, carbon black, and stone flour are 100:35:2-5:0.5:400. In the bottom layer of material, the weight proportions of polyvinyl chloride, plasticizer, stabilizer, carbon black, and stone flour are 100:25:2:0.5:100.

[0049] The manufacturing process includes the following steps: 1) Adding raw materials to a soil material layer according to the above-mentioned formula ratio and mixing the raw materials to obtain a soil material layer intermediate product, and subsequently internally mixing and calendering the soil material layer intermediate product to obtain a soil material layer sheet; 2) Adding raw materials of a middle material layer according to the above-mentioned formula ratio and mixing the raw materials to obtain a middle material layer intermediate product, and subsequently internally mixing and calendering the middle material layer intermediate product to obtain a middle material layer web; 3) Mixing, internal mixing, calendering and cutting of raw materials of the stone-plastic substrate layer to obtain a stone-plastic substrate sheet, and 4) successively arranging a first wear-resistant layer film, a color film, the middle material layer film, the stone plastic substrate layer film, the base material layer film and a second wear-resistant layer film, and then carrying out a hot pressing process to obtain a finished product.

[0050] In the hot pressing process, the pressure is regulated to 3MPa, the temperature is regulated to 125°C, and the hot pressing time is regulated to 1500s.

[0051] The cold pressing process consists of a first and a second cold pressing process. In the first cold pressing process, the pressure is regulated to 5 MPa, the temperature to 80°C, and the pressing time to 600 seconds. In the second cold pressing process, the pressure is regulated to 8 MPa, the temperature to 23°C, and the pressing time to 800 seconds.

[0052] The performance of the received product is as follows: Project name Stone plastic hot pressing hardness 65HD Expansion rate at 50°C 0,10% Shrinkage rate at 80°C 0,60% Warpage at 80°C 0.4mm Damper value 65 decibels Design Two:

[0053] A hot-pressed stone-plastic floor comprises a stone-plastic base material part, and the stone-plastic base material part comprises a middle material layer, a stone-plastic substrate layer, and a bottom material layer arranged side by side; a color film layer located on one side of an upper surface of the stone-plastic base material part; a first wear-resistant layer located on one side of an upper surface of the color film layer; and a second wear-resistant layer located on one side of a lower surface of the stone-plastic base material part; and wherein the middle material layer and the bottom material layer are mainly composed of polyvinyl chloride, dioctyl terephthalate, stabilizer, carbon black, and stone flour.

[0054] The thicknesses of the first wear-resistant layer and the second wear-resistant layer are 0.7 mm, and the thickness of the color foil layer is 0.7 mm; and the thickness of the stone plastic substrate layer is 4.0 mm, the thickness of the middle material layer is 2.0 mm, and the thickness of the bottom material layer is 1.8 mm.

[0055] The densities of the first wear-resistant layer and the second wear-resistant layer are 1.40 g / cm³. 3 The density of the stone-plastic substrate layer is 2.1 g / cm³. 3 , the density of the middle material layer is 2.0 g / cm³ 3 and the density of the soil material layer is 2.0 g / cm³ 3 .

[0056] In the middle layer of material, the weight proportions of polyvinyl chloride, plasticizer, stabilizer, carbon black and stone flour are 100:40:5:2:500.

[0057] In the soil material layer, the weight proportions of polyvinyl chloride, plasticizer, stabilizer, carbon black and stone flour are 100:35:5:2:200.

[0058] The manufacturing process includes the following steps: 1) Adding raw materials to a soil material layer according to the above-mentioned formula ratio and mixing the raw materials to obtain a soil material layer intermediate product, and subsequently internally mixing and calendering the soil material layer intermediate product to obtain a soil material layer sheet; 2) Adding raw materials of a middle material layer according to the above-mentioned formula ratio and mixing the raw materials to obtain a middle material layer intermediate product, and subsequently internally mixing and calendering the middle material layer intermediate product to obtain a middle material layer web; 3) Mixing, internal mixing, calendering and cutting of raw materials of the stone-plastic substrate layer to obtain a stone-plastic substrate sheet, and 4) successively arranging a first wear-resistant layer film, a color film, the middle material layer film, the stone plastic substrate layer film, the base material layer film and a second wear-resistant layer film, and then carrying out a hot pressing process to obtain a finished product.

[0059] In the hot pressing process, the pressure is regulated to 6 MPa, the temperature is regulated to 145°C, and the hot pressing time is regulated to 2100s.

[0060] The cold pressing process consists of a first and a second cold pressing process. In the first cold pressing process, the pressure is regulated to 8 MPa, the temperature to 145°C, and the pressing time to 800 seconds. In the second cold pressing process, the pressure is regulated to 15 MPa, the temperature to 80°C, and the pressing time to 1000 seconds.

[0061] The performance of the received product is as follows: Project name Stone plastic hot pressing hardness 62HD Shrinkage rate at 80°C 0,9% Expansion rate at 50°C 0,15% Warpage at 80°C 0.3mm Damper value 75 decibels Design Three:

[0062] A hot-pressed stone-plastic floor comprises a stone-plastic base material part, and the stone-plastic base material part comprises a middle material layer, a stone-plastic substrate layer, and a bottom material layer arranged side by side; a color film layer located on one side of an upper surface of the stone-plastic base material part; a first wear-resistant layer located on one side of an upper surface of the color film layer; and a second wear-resistant layer located on one side of a lower surface of the stone-plastic base material part; and wherein the middle material layer and the bottom material layer are mainly composed of polyvinyl chloride, dioctyl terephthalate, plasticizer, stabilizer, carbon black, and stone flour.

[0063] The thicknesses of the first wear-resistant layer and the second wear-resistant layer are 0.45 mm, and the thickness of the color foil layer is 0.45 mm; and the thickness of the stone plastic substrate layer is 2.75 mm, the thickness of the middle material layer is 1.5 mm, and the thickness of the bottom material layer is 0.05 mm.

[0064] The densities of the first wear-resistant layer and the second wear-resistant layer are 1.4 g / cm³. 3 The density of the stone-plastic substrate layer is 1.95 g / cm³. 3 , the density of the middle material layer is 1.9 g / cm³ 3 and the density of the soil material layer is 1.9 g / cm³ 3 .

[0065] In the middle layer of material, the weight proportions of polyvinyl chloride, plasticizer, stabilizer, carbon black and stone flour are 100:37.5:3.5:1.25:450.

[0066] In the soil material layer, the weight proportions of polyvinyl chloride, plasticizer, stabilizer, carbon black and stone flour are 100:30:3.5:1.25:150.

[0067] The manufacturing process includes the following steps: 1) Adding raw materials to a soil material layer according to the above-mentioned formula ratio and mixing the raw materials to obtain a soil material layer intermediate product, and subsequently internally mixing and calendering the soil material layer intermediate product to obtain a soil material layer sheet; 2) Adding raw materials of a middle material layer according to the above-mentioned formula ratio and mixing the raw materials to obtain a middle material layer intermediate product, and subsequently internally mixing and calendering the middle material layer intermediate product to obtain a middle material layer web; 3) Mixing, internal mixing, calendering and cutting of raw materials of the stone-plastic substrate layer to obtain a stone-plastic substrate sheet, and 4) successively arranging a first wear-resistant layer film, a color film, the middle material layer film, the stone plastic substrate layer film, the base material layer film and a second wear-resistant layer film, and then carrying out a hot pressing process to obtain a finished product.

[0068] In the hot pressing process, the pressure is regulated to 4.5 MPa, the temperature is regulated to 135°C, and the hot pressing time is regulated to 1800s.

[0069] The cold pressing process consists of a first and a second cold pressing process. In the first cold pressing process, the pressure is regulated to 6.5 MPa, the temperature to 112.5°C, and the pressing time to 700 seconds. In the second cold pressing process, the pressure is regulated to 11.5 MPa, the temperature to 51.5°C, and the pressing time to 900 seconds. Project name Stone plastic hot pressing hardness 63HD Expansion rate at 50°C 0,12% Shrinkage rate at 80°C 0,75% Warpage at 80°C 0.3mm Damper value 70 decibels Comparison example one:

[0070] A hot-pressed stone-plastic floor comprises a stone-plastic base material part, and the stone-plastic base material part comprises a middle material layer, a stone-plastic substrate layer, and a bottom material layer arranged side by side; a color film layer located on one side of an upper surface of the stone-plastic base material part; a first wear-resistant layer located on one side of an upper surface of the color film layer; and a second wear-resistant layer located on one side of a lower surface of the stone-plastic base material part; and wherein the middle material layer and the bottom material layer are mainly composed of polyvinyl chloride, dioctyl terephthalate, stabilizer, carbon black, and stone flour.

[0071] The thicknesses of the first wear-resistant layer and the second wear-resistant layer are 0.85 mm, and the thickness of the color foil layer is 0.85 mm; and the thickness of the stone plastic substrate layer is 4.1 mm, the thickness of the middle material layer is 1.9 mm, and the thickness of the bottom material layer is 1.7 mm.

[0072] The densities of the first wear-resistant layer and the second wear-resistant layer are 1.25 g / cm³. 3 The density of the stone-plastic substrate layer is 3.4 g / cm³. 3 , the density of the middle material layer is 1.8 g / cm³ 3 and the density of the soil material layer is 1.8 g / cm³ 3 .

[0073] In the middle layer of material, the weight proportions of polyvinyl chloride, plasticizer, stabilizer, carbon black and stone flour are 100:42:7:3:600.

[0074] In the soil material layer, the weight proportions of polyvinyl chloride, plasticizer, stabilizer, carbon black and stone flour are 100:37:7:3:300.

[0075] The manufacturing process includes the following steps: 1) Adding raw materials to a soil material layer according to the above-mentioned formula ratio and mixing the raw materials to obtain a soil material layer intermediate product, and subsequently internally mixing and calendering the soil material layer intermediate product to obtain a soil material layer sheet; 2) Adding raw materials of a middle material layer according to the above-mentioned formula ratio and mixing the raw materials to obtain a middle material layer intermediate product, and subsequently internally mixing and calendering the middle material layer intermediate product to obtain a middle material layer web; 3) Mixing, internal mixing, calendering and cutting of raw materials of the stone-plastic substrate layer to obtain a stone-plastic substrate sheet, and 4) successively arranging a first wear-resistant layer film, a color film, the middle material layer film, the stone plastic substrate layer film, the base material layer film and a second wear-resistant layer film, and then carrying out a hot pressing process to obtain a finished product.

[0076] In the hot pressing process, the pressure is regulated to 6.0 MPa, the temperature is regulated to 160°C, and the hot pressing time is regulated to 2300s.

[0077] The cold pressing process consists of a first and a second cold pressing process. In the first cold pressing process, the pressure is regulated to 9 MPa, the temperature to 155°C, and the pressing time to 900 seconds. In the second cold pressing process, the pressure is regulated to 17 MPa, the temperature to 90°C, and the pressing time to 1200 seconds.

[0078] The product performance of ordinary stone-plastic flooring on the existing market: Project name Stone plastic hot pressing hardness 63HD Expansion rate at 50°C 0,20% Shrinkage rate at 80°C 1,21% Warpage at 80°C 0.5mm Damper value 90 decibels

[0079] The product performance of the stone-plastic flooring currently available on the market is as follows: Project name Stone plastic hot pressing hardness 75HD Expansion rate at 50°C 0,32% Shrinkage rate at 80°C 1,75% Warpage at 80°C 0.7mm Damper value 105 decibels

[0080] In summary, embodiments one and two show that by using the technology within the process scope, the density and hardness of the resulting hot-pressed stone-plastic flooring are lower than those of the existing product; while the expansion rate at 50°C, the shrinkage rate at 80°C, and the damping value are much lower than those of the existing products, thus greatly increasing product performance.

[0081] Comparative example one shows that when the process scope in embodiments one and two is exceeded, the hardness, the expansion rate at 50°C, the shrinkage rate at 80°C and the distortion at 80°C are closer to those of the existing products, but are significantly below the product performance in embodiment one, embodiment two and embodiment three.

[0082] The foregoing descriptions are merely preferred embodiments of the present invention and therefore do not limit the scope of patent protection of the present invention. Any equivalent structural transformation carried out by using the contents of the description of the present invention or by directly or indirectly applying the present invention to other related technical fields is included within the scope of protection of the present invention.

Claims

[1] Stone-plastic hot-pressed flooring, comprising: a stone-plastic base material part comprising a middle material layer, a stone-plastic substrate layer and a bottom material layer arranged side by side in succession; a colored foil layer located on one side of an upper surface of the stone-plastic base material component; a first wear-resistant layer located on one side of an upper surface of the color film layer, and a second wear-resistant layer located on one side of a lower surface of the stone-plastic base material component; where both the middle material layer and the bottom material layer are mainly composed of polyvinyl chloride, plasticizer, stabilizer, carbon black and stone flour. [2] The stone-plastic hot-pressed floor covering according to claim 1, wherein both the thickness of the first wear-resistant layer and the thickness of the second wear-resistant layer are in the range of 0.07-0.7 mm, and the thickness of the color foil layer is in the range of 0.07-0.7 mm, and the thickness of the stone-plastic substrate layer is in the range of 1.5-4.0 mm, and the thickness of the middle material layer is in the range of 1.8-2.0 mm and the thickness of the floor material layer is in the range of 1.6-1.8 mm. [3] The stone-plastic hot-pressed floor covering according to claim 2, wherein both the density of the first wear-resistant layer and the density of the second wear-resistant layer are in the range of 1.10-1.40 g / cm³ 3 lay. [4] The stone-plastic hot-pressed floor covering according to claim 3, wherein the density of the stone-plastic substrate layer is in the range of 1.8-2.1 g / cm³ 3The density of the middle material layer is in the range of 1.6-2.0 g / cm³. 3 lies, and a density of the soil material layer in the range of 1.6-2.0 g / cm³ 3 lies. [5] The stone-plastic hot-pressed floor covering according to claim 1, wherein the weight fractions of the polyvinyl chloride, plasticizer, stabilizer, carbon black and stone flour in the middle material layer are 100:(35-40):(2-5):(0.5-2):(400-500). [6] The stone-plastic hot-pressed floor covering according to claim 1, wherein the weight fractions of the polyvinyl chloride, plasticizer, stabilizer, carbon black and stone flour in the floor material layer are 100:(25-35):(2-5):(0.5-2):(100-200). [7] The stone-plastic hot-pressed floor covering according to claim 1, wherein the plasticizer is made from dioctyl terephthalate. [8] The stone-plastic hot-pressed floor covering according to one of claims 1-7, wherein the shrinkage rate of the stone-plastic hot-pressed floor covering is in the range of 0.60%-0.90%. [9] The stone-plastic hot-pressed floor covering according to one of claims 1-7, wherein the expansion rate of the stone-plastic hot-pressed floor covering is in the range of 0.10%-0.15%. [10] The stone-plastic hot-pressed floor covering according to one of claims 1-7, wherein a damping value of the stone-plastic hot-pressed floor covering is in the range of 65-75 decibels. [11] A manufacturing process for stone-plastic hot-pressed flooring, wherein the stone-plastic hot-pressed flooring is the stone-plastic hot-pressed flooring according to any one of claims 1-10, the manufacturing process comprising the following steps: Adding and mixing raw materials of the soil material layer according to components as claimed in any one of claims 1-10 to obtain a soil material layer intermediate product, and subsequently internally mixing and calendering the soil material layer intermediate product to obtain a soil material layer web; Adding and mixing raw materials of the middle material layer according to components as claimed in any one of claims 1-10 to obtain a middle material layer intermediate product, and subsequently internally mixing and calendering the middle material layer intermediate product to obtain a middle material layer web; Mixing, internal mixing and calendering of raw materials of the stone-plastic substrate layer to obtain a stone-plastic substrate layer sheet, and successive arrangement of a first wear-resistant layer film, a color film, the middle material layer film, the stone plastic substrate layer film, the base material layer film and a second wear-resistant layer film, and then carrying out a hot pressing process to obtain a finished product. [12] The manufacturing process of the stone-plastic hot-pressed floor covering according to claim 11, wherein in the hot-pressing process a pressure is regulated in a range of 3-6 MPa, a temperature is regulated in a range of 125-145 °C and a hot-pressing time is regulated in a range of 1500-2100 s. [13] The manufacturing process of the stone-plastic hot-pressed flooring according to claim 11, further comprising a cold pressing process, wherein the cold pressing process is carried out after the hot pressing process and comprises a first cold pressing process and a second cold pressing process. [14] The manufacturing process of the stone-plastic hot-pressed flooring according to claim 13, wherein in the first cold pressing process a pressure is regulated in a range of 5-8 MPa, a temperature is regulated in a range of 80-145 °C and a cold pressing time is regulated in a range of 600-800s. [15] The manufacturing process of the stone-plastic hot-pressed flooring according to claim 13, wherein in the second cold-pressing process a pressure is regulated in a range of 8-15 MPa, a temperature is regulated in a range of 23-80 °C and a cold-pressing time is regulated in a range of 800-1000 s. [16] The manufacturing process of the stone-plastic hot-pressed flooring according to claim 11, further comprising a cutting process after calendering the floor material layer intermediate product or the middle material layer intermediate product or the stone-plastic substrate layer.