HOT-PRESSED STONE-PLASTIC FLOOR COVERING AND METHOD FOR MANUFACTURING THE SAME

Abstract

Title: Stone-plastic hot-pressing floor covering and manufacturing method therefor Provided is a stone-plastic hot-pressing floor covering including a stone-plastic base material part including a core material layer, a stone-plastic substrate layer and a bottom material layer sequentially 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 core material layer and the bottom material layer are mainly composed of polyvinyl chloride, plasticizer, stabilizer, carbon black and stone powder.A tension balance of the stone-plastic substrate layer is achieved by symmetrically arranging the middle material layer and the lower material layer with respect to the stone-plastic substrate layer, constituting the middle material layer and the lower material layer mainly with polyvinyl chloride, plasticizer, stabilizer, carbon black and stone powder, and symmetrically arranging the first wear-resistant layer and the second wear-resistant layer. Under a condition of stability of the product, its density is reduced, the foot feel is improved and the mute value is reduced.

Description

Title of the invention: Stone-plastic hot-pressed floor covering and method of manufacturing the same Technical field of the invention

[0001] The present invention relates to a stone-plastic hot-pressed floor covering and a method of manufacturing the same and, more particularly, to the field of a building material. Prior art

[0002] Stone-plastic flooring, which is also called stone-plastic slab, is a new high-quality decorative material for the floor that has undergone high-tech research and development. Natural marble powder is used to form a solid base layer with a high-density and fiber-rich mesh structure, and one surface is covered with a super wear-resistant PVC polymer wear-resistant layer, which is processed through hundreds of processes.

[0003] Compared with other floor decorative materials, stone-plastic flooring has the following advantages. 1) It is green and environmentally friendly: The main raw material in the production of stone-plastic flooring is natural stone powder, which is a new green and environmentally friendly floor decoration material. 2) The stability of stone-plastic is good, it is free from any camber and warping. 3) Super wear-resistant: A special transparent wear-resistant layer processed by high technology is present, and the wear-resistant rotation speed can reach up to 300,000 rpm.In traditional flooring materials, the wear-resistant rotation speed of a relatively wear-resistant laminate flooring is only 13,000 rpm, and that of a good laminate flooring is only 20,000 rpm. The super wear-resistant layer with a specially treated surface fully guarantees the excellent wear-resistant property of the flooring materials. Under normal circumstances, the wear-resistant layer of the stone-plastic flooring surface can be used for 5 to 10 years depending on the different thickness. The thickness and quality of the wear-resistant layer directly determine the service life of the stone-plastic flooring.The standardized test result shows that the 0.55mm thick wear-resistant layer coating can be used for more than 5 years under normal circumstances, the 0.7mm thick wear-resistant layer floor can be used for more. 10 years, so it is even super wear-resistant. Due to the property of super wear resistance, stone-plastic flooring is increasingly popular in hospitals, schools, office buildings, shopping malls, supermarkets and other places with a relatively large flow of people. 4) High elasticity and super impact resistance: The elasticity of stone-plastic flooring is very good because the texture is relatively soft, and the stone-plastic flooring provides fine elastic recovery under the impact of heavy objects. The foot feeling is pleasant, even referred to as "the soft gold of flooring materials". In addition, stone-plastic flooring has strong impact resistance, providing strong elastic recovery after impact and damage by heavy objects, for strong protection against damage.Excellent stone-plastic flooring can minimize the impact of the floor on the human body and spread the shock to the foot. The latest research data shows that in a space with a relatively large flow of people, after installing excellent stone-plastic flooring, the frequency of falls and injuries to personnel is reduced by almost 70% compared to other flooring. 5) Super anti-slip: The wear-resistant layer of the stone-plastic flooring surface has a special anti-slip property, and compared with ordinary floor materials, in the case of sticky water, the foot feeling is harder and it is not easy to slip. In other words, the more water there is, the harder the feeling. 6) Fireproof: The fire resistance index of quality stone-plastic flooring can reach Bl level. B1 level means that the fire resistance performance is very good, second only to that of stone.

[0004] The existing stone-plastic hot-pressing flooring has defects of high mute value, relatively high density and poor foot feeling. Summary of the invention

[0005] Technical problems of stone-plastic hot pressing flooring to be solved

[0006] The objective of the present invention is to provide a stone-plastic hot-pressing floor covering which can overcome defects of relatively high density, poor foot feel and high mute value in the existing stone-plastic hot-pressing floor covering. Technical solution

[0007] To solve the above-mentioned technical problem, the present invention provides a stone-plastic hot-pressing floor covering including a part of A stone-plastic base material including a core material layer, a stone-plastic substrate layer, and a bottom material layer sequentially arranged side by side; a colored film layer, located on one side of an upper surface of the stone-plastic base material portion; 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 portion; wherein the core material layer and the bottom material layer are both mainly composed of polyvinyl chloride, plasticizer, stabilizer, carbon black, and stone powder.

[0008] In the present invention, the tension balance of the stone-plastic substrate layer is achieved by symmetrically arranging the middle material layer and the lower material layer with respect to the stone-plastic substrate layer, constituting the middle material layer and the lower material layer mainly with polyvinyl chloride, plasticizer, stabilizer, carbon black and stone powder, and symmetrically arranging the first wear-resistant layer and the second wear-resistant layer. Under the condition that the stability of the product is ensured, the density of the product is reduced, the foot feel is improved and the mute value is reduced.

[0009] Optionally, the thicknesses of the first wear-resistant layer and the second wear-resistant layer are both in a range of 0.07 to 0.7 mm, and a thickness of the colored film layer is in a range of 0.07 to 0.7 mm; and a thickness of the stone-plastic substrate layer is in a range of 1.5 to 4.0 mm, a thickness of the middle material layer is in a range of 1.8 to 2.0 mm, and a thickness of the lower material layer is in a range of 1.6 to 1.8 mm.

[0010] Optionally, the densities of the first wear-resistant layer and the second wear-resistant layer are both in a range of 1.10 to 1.40 g / cm3.

[0011] Optionally, a density of the stone-plastic substrate layer is in a range of 1.8 to 2.1 g / cm3, a density of the middle material layer is in a range of 1.6 to 2.0 g / cm3 and a density of the bottom material layer is in a range of 1.6 to 2.0 g / cm3.

[0012] Optionally, parts by weight of the polyvinyl chloride, plasticizer, stabilizer, carbon black and stone powder in the core material layer are 100:(35 to 40):(2 to 5):(0.5 to 2):(400 to 500).

[0013] Optionally, parts by weight of the polyvinyl chloride, plasticizer, stabilizer, carbon black and stone powder in the lower material layer are 100:(25 to 35):(2 to 5):(0.5 to 2):(100 to 200).

[0014] Optionally, the plasticizer consists of dioctyl terephthalate.

[0015] Optionally, a contraction rate of the floor covering by hot pressing of stone-plastic is in the range of 0.60% to 0.90%.

[0016] Optionally, an expansion rate of the stone-plastic hot pressing floor covering is in a range of 0.10% to 0.15%.

[0017] Optionally, a mute value of the stone-plastic hot pressing floor covering is in a range of 65 to 75 decibels.

[0018] The present invention further provides a method of manufacturing the aforementioned stone-plastic hot pressing floor covering including the following steps: adding and mixing raw materials of the lower material layer according to the above-mentioned constituents to obtain a lower material layer intermediate, then internally mixing and calendering the lower material layer intermediate to obtain a lower material layer sheet; adding and mixing raw materials of the core material layer according to the above-mentioned constituents to obtain a core material layer intermediate, then internally mixing and calendering the core material layer intermediate to obtain a core material layer sheet; mixing, internal mixing and calendering of raw materials of the stone-plastic substrate layer to obtain a stone-plastic substrate layer sheet; and sequentially arranging a first wear-resistant layer film, a colored film, the middle material layer sheet, the stone-plastic substrate layer sheet, the lower material layer sheet and a second wear-resistant layer film, and then performing a hot pressing process to obtain a finished product.

[0019] Optionally, in the hot pressing process, a pressure is regulated in a range of 3 to 6 MPa, a temperature is regulated in a range of 125 to 145°C and a hot pressing time is regulated in a range of 1500 to 2100 s.

[0020] Optionally, the method of manufacturing the stone-plastic hot pressing flooring further includes a cold pressing process. 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.

[0021] In the first cold pressing process, a pressure is regulated in a range of 5 to 8 MPa, a temperature is regulated in a range of 80 to 145°C and a cold pressing time is regulated in a range of 600 to 800 s.

[0022] Optionally, in the second cold pressing process, a pressure is regulated in a range of 8 to 15 MPa, a temperature is regulated in a range of 23 to 80°C and a cold pressing time is regulated in a range of 800 to 1000 s.

[0023] Optionally, after calendering the bottom material layer intermediate, the middle material layer intermediate or the stone-plastic substrate layer, a slicing operation is further included.

[0024] Beneficial effects

[0025] The present invention provides a stone-plastic hot-pressed floor covering having the following advantages.

[0026] In the present invention, by increasing the core material layer and the bottom material layer and regulating the weight ratio of the core material layer and the bottom material layer, a locking tensile force of the stone-plastic hot pressing flooring is increased, at the same time, the density and hardness of the product are decreased, and the decrease in the hardness of the product improves the foot feeling thereof. Detailed description of the invention

[0027] A specific implementation of the present invention is described in more detail below in combination with embodiments. The following embodiments are used to illustrate the present invention, but are not intended to limit the scope of the present invention.

[0028] All "a" or "an" in the present invention should be interpreted as "at least one or an" or "one or two or more".

[0029] The present invention provides a stone-plastic hot-pressing floor covering including a stone-plastic base material portion which includes a core material layer, a stone-plastic substrate layer and a bottom material layer sequentially arranged side by side; a colored film layer, located on one side of an upper surface of the stone-plastic base material portion; 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 portion; and wherein the core material layer and the bottom material layer are both mainly composed of polyvinyl chloride, plasticizer, stabilizer, carbon black and stone powder.

[0030] The thicknesses of the first wear-resistant layer and the second wear-resistant layer are both in a range of 0.07-0.7 mm, and a thickness of the colored film layer is in a range of 0.07-0.7 mm; and a thickness of the stone-plastic substrate layer is in a range of 1.5-4.0 mm, a thickness of the middle material layer is in a range of 1.8-2.0 mm, and a thickness of the lower material layer is in a range of 1.6-1.8 mm.

[0031] The densities of the first wear-resistant layer and the second wear-resistant layer are in a range of 1.10 to 1.40 g / cm3.

[0032] A density of the stone-plastic substrate layer is in a range of 1.8 to 2.1 g / cm3, a density of the middle material layer is in a range of 1.6 to 2.0 g / cm3 and a density of the lower material layer is in a range of 1.6 to 2.0 g / cm3.

[0033] Parts by weight of the polyvinyl chloride, plasticizer, stabilizer, carbon black and stone powder in the core material layer are 100:(35 to 40):(2 to 5):(0.5 to 2):(400 to 500).

[0034] Parts by weight of the polyvinyl chloride, plasticizer, stabilizer, carbon black and stone powder in the lower material layer are 100:(25 to 35):(2 to 5):(0.5 to 2):(100 to 200).

[0035] The plasticizer consists of dioctyl terephthalate.

[0036] A contraction rate of the floor covering by hot pressing of stone-plastic is in a range of 0.60% to 0.90%.

[0037] An expansion rate of the stone-plastic hot pressing floor covering is in a range of 0.10% to 0.15%.

[0038] A mute value of the stone-plastic hot pressing floor covering is in a range of 65 to 75 decibels.

[0039] The present invention further provides a method of manufacturing the aforementioned stone-plastic hot pressing floor covering including the following steps: adding and mixing raw materials of the lower material layer according to the above formula ratio to obtain a lower material layer intermediate, and then internally mixing and calendering the lower material layer intermediate to obtain a lower material layer sheet; adding and mixing core material layer raw materials according to the above formula ratio to obtain a core material layer intermediate, and then internally mixing and calendering the core material layer intermediate to obtain a core material layer sheet; mixing, internal mixing and calendering of raw materials of the stone-plastic substrate layer to obtain a stone-plastic substrate layer sheet; and sequentially arranging a first wear-resistant layer film, a colored film, the middle material layer sheet, the stone-plastic substrate layer sheet, the lower material layer sheet and a second wear-resistant layer film, and then performing a hot pressing process to obtain a finished product.

[0040] In the hot pressing process, a pressure is regulated in a range of 3 to 6 MPa, a temperature is regulated in a range of 125 to 145°C, and a hot pressing time is regulated in a range of 1500 to 2100 s.

[0041] The method for manufacturing the stone-plastic hot pressing floor covering further includes a cold pressing process. 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.

[0042] In the first cold pressing process, a pressure is regulated in a range of 5 to 8 MPa, a temperature is regulated in a range of 80 to 145°C and a cold pressing time is regulated in a range of 600 to 800 s.

[0043] In the second cold pressing process, a pressure is regulated in a range of 8 to 15 MPa, a temperature is regulated in a range of 23 to 80°C and a cold pressing time is regulated in a range of 800 to 1000 s.

[0044] After calendering the lower material layer intermediate, the middle material layer intermediate or the stone-plastic substrate layer, a slicing operation is further included.

[0045] The formula of the stone-plastic substrate layer of the present embodiment is:

[0046] [Tables 1] Name Quantity (kg) PVC-SG5 50 stone powder at 400 mesh 110 stabilizer 6 stearic acid 0.7 PE wax 0.6 ACR 4 CPE (chlorinated polyethylene) 4

[0047] ACR is a range of impact resistance modifiers.

[0048] A specific description is made by embodiments below.

[0049] First embodiment:

[0050] A stone-plastic hot-pressing floor covering includes a stone-plastic base material portion, and the stone-plastic base material portion includes a core material layer, a stone-plastic substrate layer, and a bottom material layer sequentially arranged side by side; a colored film layer, located on one side of an upper surface of the stone-plastic base material portion; 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 portion; and wherein the core material layer and the bottom material layer are both mainly composed of polyvinyl chloride, dioctyl terephthalate, plasticizer, stabilizer, carbon black, and stone powder.

[0051] Thicknesses of the first wear-resistant layer and the second wear-resistant layer are 0.07 mm and a thickness of the colored film layer is 0.07 mm; and a thickness of the stone-plastic substrate layer is 1.5 mm, a thickness of the middle material layer is 1.8 mm and a thickness of the lower material layer is 1.6 mm.

[0052] Densities of the first wear-resistant layer and the second wear-resistant layer are 1.10 g / cm3. A density of the stone-plastic substrate layer is 1.8 g / cm3, a density of the middle material layer is 1.6 g / cm3 and a density of the bottom material layer is 1.6 g / cm3.

[0053] Parts by weight of poly(vinyl chloride), plasticizer, stabilizer, carbon black and stone powder in the middle material layer are 100:35:2 to 5:0.5:400. Parts by weight of poly(vinyl chloride), plasticizer, stabilizer, carbon black and stone powder in the lower material layer are 100:25:2:0.5:100.

[0054] Its manufacturing process includes the following steps: 1) adding raw materials of a lower material layer according to the above-mentioned formula ratio and mixing the raw materials to obtain a lower material layer intermediate, then internally mixing and calendering the lower material layer intermediate to obtain a lower material layer sheet; 2) adding raw materials of a core material layer according to the above-mentioned formula ratio and mixing the raw materials to obtain a core material layer intermediate, then internally mixing and calendering the core material layer intermediate to obtain a core material layer sheet; 3) mixing, internal mixing, calendering and slicing raw materials of the stone-plastic substrate layer to obtain a stone-plastic substrate layer sheet; and 4) sequentially arranging a first wear-resistant layer film, a colored film, the middle material layer sheet, the stone-plastic substrate layer sheet, the lower material layer sheet and a second wear-resistant layer film, and then carrying out a hot pressing process to obtain a finished product.

[0055] In the hot pressing process, a pressure is regulated at 3 MPa, a temperature is regulated at 125°C and a hot pressing time is regulated at 1500 s.

[0056] The cold pressing process includes a first cold pressing process and a second cold pressing process. In the first cold pressing process, a pressure is regulated at 5 MPa, a temperature is regulated at 80°C and a cold pressing time is regulated at 600 s. In the second cold pressing process, a pressure is regulated at 8 MPa, a temperature is regulated at 23°C and a cold pressing time is regulated at 800 s.

[0057] The performance of the product obtained is as follows:

[0058] [Tables2] Project Name Stone-plastic hot pressing Hardness 65HD Expansion rate at 50°C 0.10% Contraction rate at 80°C 0.60% Warpage at 80°C 0.4 mm Mute value 65 decibels

[0059] Second embodiment:

[0060] A stone-plastic hot-pressing floor covering includes a stone-plastic base material portion, and the stone-plastic base material portion includes a core material layer, a stone-plastic substrate layer, and a bottom material layer sequentially arranged side by side; a colored film layer, located on one side of an upper surface of the stone-plastic base material portion; 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 portion; and wherein the core material layer and the bottom material layer are both mainly composed of polyvinyl chloride, dioctyl terephthalate, plasticizer, stabilizer, carbon black, and stone powder.

[0061] Thicknesses of the first wear-resistant layer and the second wear-resistant layer are 0.7 mm, and a thickness of the colored film layer is 0.7 mm; and a thickness of the stone-plastic substrate layer is 4.0 mm, a thickness of the middle material layer is 2.0 mm, and a thickness of the lower material layer is 1.8 mm.

[0062] Densities of the first wear-resistant layer and the second wear-resistant layer are 1.40 g / cm3. A density of the stone-plastic substrate layer is 2.1 g / cm3, a density of the middle material layer is 2.0 g / cm3, and a density of the bottom material layer is 2.0 g / cm3.

[0063] Parts by weight of poly(vinyl chloride), plasticizer, stabilizer, carbon black and stone powder in the core material layer are 100:40:5:2:500.

[0064] Parts by weight of poly(vinyl chloride), plasticizer, stabilizer, carbon black and stone powder in the lower material layer are 100:35:5:2:200.

[0065] Its manufacturing process includes the following steps: 1) adding raw materials of a lower material layer according to the above-mentioned formula ratio and mixing the raw materials to obtain a lower material layer intermediate, then internally mixing and calendering the lower material layer intermediate to obtain a lower material layer sheet; 2) adding raw materials of a core material layer according to the above-mentioned formula ratio and mixing the raw materials to obtain a core material layer intermediate, then internally mixing and calendering the core material layer intermediate to obtain a core material layer sheet; 3) mixing, internal mixing, calendering and slicing raw materials of the stone-plastic substrate layer to obtain a stone-plastic substrate layer sheet; and 4) sequentially arranging a first wear-resistant layer film, a colored film, the middle material layer sheet, the stone-plastic substrate layer sheet, the lower material layer sheet and a second wear-resistant layer film, and then carrying out a hot pressing process to obtain a finished product.

[0066] In the hot pressing process, a pressure is regulated at 6 MPa, a temperature is regulated at 145°C and a hot pressing time is regulated at 2100 s.

[0067] The cold pressing process includes a first cold pressing process and a second cold pressing process. In the first cold pressing process, a pressure is regulated at 8 MPa, a temperature is regulated at 145°C, and a cold pressing time is regulated at 800 s. In the second cold pressing process, a pressure is regulated at 15 MPa, a temperature is regulated at 80°C, and a cold pressing time is regulated at 1000 s.

[0068] The performance of the product obtained is as follows:

[0069] [Tables3] Project name Stone-plastic hot pressing hardness 62HD expansion rate at 50°C 0.15% contraction rate at 80°C 0.9% warpage at 80°C 0.3mm mute value 75 decibels

[0070] Third embodiment:

[0071] A stone-plastic hot-pressing floor covering includes a stone-plastic base material portion, and the stone-plastic base material portion includes a core material layer, a stone-plastic substrate layer, and a bottom material layer sequentially arranged side by side; a colored film layer, located on one side of an upper surface of the stone-plastic base material portion; 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 portion; and wherein the core material layer and the bottom material layer are both mainly composed of polyvinyl chloride, dioctyl terephthalate, plasticizer, stabilizer, carbon black, and stone powder.

[0072] Thicknesses of the first wear-resistant layer and the second wear-resistant layer are 0.45 mm, and a thickness of the colored film layer is 0.45 mm; and a thickness of the stone-plastic substrate layer is 2.75 mm, a thickness of the middle material layer is 1.5 mm, and a thickness of the lower material layer is 0.05 mm.

[0073] Densities of the first wear-resistant layer and the second wear-resistant layer are 1.4 g / cm3. A density of the stone-plastic substrate layer is 1.95 g / cm3, a density of the middle material layer is 1.9 g / cm3 and a density of the bottom material layer is 1.9 g / cm3.

[0074] Parts by weight of poly(vinyl chloride), plasticizer, stabilizer, carbon black and stone powder in the core material layer are 100:37.5:3.5:1.25:150.

[0075] Parts by weight of poly(vinyl chloride), plasticizer, stabilizer, carbon black and stone powder in the lower material layer are 100:30:3.5:1.25:450.

[0076] Its manufacturing process includes the following steps: 1) adding raw materials of a lower material layer according to the above-mentioned formula ratio and mixing the raw materials to obtain a lower material layer intermediate, then internally mixing and calendering the lower material layer intermediate to obtain a lower material layer sheet; 2) adding raw materials of a core material layer according to the above-mentioned formula ratio and mixing the raw materials to obtain a core material layer intermediate, then internally mixing and calendering the core material layer intermediate to obtain a core material layer sheet; 3) mixing, internal mixing, calendering and slicing raw materials of the stone-plastic substrate layer to obtain a stone-plastic substrate layer sheet; and 4) sequentially arranging a first wear-resistant layer film, a colored film, the middle material layer sheet, the stone-plastic substrate layer sheet, the lower material layer sheet and a second wear-resistant layer film, and then carrying out a hot pressing process to obtain a finished product.

[0077] In the hot pressing process, a pressure is regulated at 4.5 MPa, a temperature is regulated at 135°C and a hot pressing time is regulated at 1800 s.

[0078] The cold pressing process includes a first cold pressing process and a second cold pressing process. In the first cold pressing process, a pressure is regulated at 6.5 MPa, a temperature is regulated at 112.5°C, and a cold pressing time is regulated at 700 s. In the second cold pressing process, a pressure is regulated at 11.5 MPa, a temperature is regulated at 51.5°C, and a cold pressing time is regulated at 900 s.

[0079] [Tables4] Project name Stone-plastic hot pressing hardness 63HD expansion rate at 50°C 0.12% contraction rate at 80°C 0.75% warpage at 80°C 0.3 mm mute value 70 decibels

[0080] Comparative example one:

[0081] A stone-plastic hot-pressing floor covering includes a stone-plastic base material portion, and the stone-plastic base material portion A plastic includes a core material layer, a stone-plastic substrate layer, and a bottom material layer sequentially arranged side by side; a colored film layer, located on one side of an upper surface of the stone-plastic base material portion; 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 portion; and wherein the core material layer and the bottom material layer are both mainly composed of polyvinyl chloride, dioctyl terephthalate, plasticizer, stabilizer, carbon black, and stone powder.

[0082] Thicknesses of the first wear-resistant layer and the second wear-resistant layer are 0.85 mm, and a thickness of the colored film layer is 0.85 mm; and a thickness of the stone-plastic substrate layer is 4.1 mm, a thickness of the middle material layer is 1.9 mm, and a thickness of the lower material layer is 1.7 mm.

[0083] Densities of the first wear-resistant layer and the second wear-resistant layer are 1.25 g / cm3. A density of the stone-plastic substrate layer is 3.4 g / cm3, a density of the middle material layer is 1.8 g / cm3, and a density of the bottom material layer is 1.8 g / cm3.

[0084] Parts by weight of poly(vinyl chloride), plasticizer, stabilizer, carbon black and stone powder in the core material layer are 100:42:7:3:600.

[0085] Parts by weight of poly(vinyl chloride), plasticizer, stabilizer, carbon black and stone powder in the lower material layer are 100:37:7:3:300.

[0086] Its manufacturing process includes the following steps: 1) adding raw materials of a lower material layer according to the above-mentioned formula ratio and mixing the raw materials to obtain a lower material layer intermediate, then internally mixing and calendering the lower material layer intermediate to obtain a lower material layer sheet; 2) adding raw materials of a core material layer according to the above-mentioned formula ratio and mixing the raw materials to obtain a core material layer intermediate, then internally mixing and calendering the core material layer intermediate to obtain a core material layer sheet; 3) mixing, internal mixing, calendering and slicing raw materials of the stone-plastic substrate layer to obtain a stone-plastic substrate layer sheet; and 4) sequentially arranging a first wear-resistant layer film, a colored film, the middle material layer sheet, the stone-plastic substrate layer sheet, the lower material layer sheet and a second wear-resistant layer film, and then carrying out a hot pressing process to obtain a finished product.

[0087] In the hot pressing process, a pressure is regulated at 6.0 MPa, a temperature is regulated at 160°C and a hot pressing time is regulated at 2300 s.

[0088] The cold pressing process includes a first cold pressing process and a second cold pressing process. In the first cold pressing process, a pressure is regulated at 9 MPa, a temperature is regulated at 155°C, and a cold pressing time is regulated at 900 s. In the second cold pressing process, a pressure is regulated at 17 MPa, a temperature is regulated at 90°C, and a cold pressing time is regulated at 1200 s.

[0089] The product performance of ordinary stone-plastic flooring in the existing market is:

[0090] [Tables5] Project Name Stone-plastic hot pressing Hardness 63HD Expansion rate at 50°C 0.20% Contraction rate at 80°C 1.21% Warpage at 80°C 0.5mm Mute value 90 decibels

[0091] The product performance of the existing stone-plastic floor covering on the market is:

[0092] [Tableauxô] Project name Stone-plastic hot pressing hardness 75HD expansion rate at 50°C 0.32% contraction rate at 80°C 1.75% warpage at 80°C 0.7mm mute value 105 decibels

[0093] In summary, it can be seen from the first and second embodiments, by using the technology within the process scope, that the density of the obtained hot-pressing stone-plastic flooring is lower than that of the existing product and the hardness is lower than that of the existing product; while the expansion rate at 50°C, the contraction rate at 80°C and the mute value are much lower than those of the existing products, thereby greatly improving the product yield.

[0094] From comparative example one, it can be seen that when exceeding the process scope in the first and second embodiments, the hardness, expansion rate at 50°C, contraction rate at 80°C and warpage at 80°C are much closer to those of existing products, which is much further below the product performance in the first, second and third embodiments.

[0095] The above description relates only to preferred embodiments of the present invention and therefore should not limit the scope of protection in terms of patent of the present invention. Any equivalent structural transformation carried out by using the contents of the specification of the present invention or by directly or indirectly applying the present invention to other related technical fields is included in the scope of protection of the present invention.

Claims

Claims

1. A stone-plastic hot-pressing floor covering, comprising: a stone-plastic base material portion, including a core material layer, a stone-plastic substrate layer, and a bottom material layer sequentially arranged side by side; a colored film layer, located on one side of an upper surface of the stone-plastic base material portion; 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 portion;wherein the core material layer and the lower material layer are both mainly composed of polyvinyl chloride, plasticizer, stabilizer, carbon black and stone powder, parts by weight of the polyvinyl chloride, plasticizer, stabilizer, carbon black and stone powder in the core material layer being 100:(35 to 40):(2 to 5):(0.5 to 2):(400 to 500), and parts by weight of the polyvinyl chloride, plasticizer, stabilizer, carbon black and stone powder in the lower material layer being 100:(25 to 35):(2 to 5):(0.5 to 2):(100 to 200).;

2. The stone-plastic hot-pressing flooring according to claim 1, wherein a thickness of the first wear-resistant layer and a thickness of the second wear-resistant layer are both in a range of 0.07 to 0.7 mm and a thickness of the colored film layer is in a range of 0.07 to 0.7 mm; and a thickness of the stone-plastic substrate layer is in a range of 1.5 to 4.0 mm, a thickness of the middle material layer is in a range of 1.8 to 2.0 mm and a thickness of the lower material layer is in a range of 1.6 to 1.8 mm.

3. A stone-plastic hot-pressing floor covering according to claim 2, wherein a density of the first wear-resistant layer and a density of the second wear-resistant layer are both in a range of 1.10 to 1.40 g / cm3.

4. The stone-plastic hot-pressing floor covering according to claim 3, wherein a density of the stone-plastic substrate layer is in a range of 1.8 to 2.1 g / cm3, a density of the middle material layer is in a range of 1.6 to 2.0 g / cm3, and a density of the lower material layer is in a range of 1.6 to 2.0 g / cm3.

5. A stone-plastic hot-pressed floor covering according to claim 1, wherein the plasticizer is dioctyl terephthalate.

6. A stone-plastic hot-pressing floor covering according to any one of claims 1 to 5, wherein a contraction rate of the stone-plastic hot-pressing floor covering is in a range of 0.60% to 0.90%.

7. A stone-plastic hot-pressing floor covering according to any one of claims 1 to 5, wherein an expansion rate of the stone-plastic hot-pressing floor covering is in a range of 0.10% to 0.15%.

8. A stone-plastic hot-pressing floor covering according to any one of claims 1 to 5, wherein a mute value of the stone-plastic hot-pressing floor covering is in a range of 65 to 75 decibels.

9. A method of manufacturing a stone-plastic hot-pressing floor covering, wherein the stone-plastic hot-pressing floor covering is the stone-plastic hot-pressing floor covering according to any one of claims 1 to 8, the manufacturing method comprising the following steps: adding and mixing raw materials of the lower material layer according to the components according to any one of claims 1 to 8 to obtain a lower material layer intermediate, and then internally mixing and calendering the lower material layer intermediate to obtain a lower material layer sheet; adding and mixing the core material layer raw materials according to the components according to any one of claims 1 to 8 to obtain a core material layer intermediate, then internally mixing and calendering the core material layer intermediate to obtain a core material layer sheet; mixing, internally mixing and calendering stone-plastic substrate layer raw materials to obtain a stone-plastic substrate layer sheet; and sequentially arranging a first wear-resistant layer film, a colored film, the core material layer sheet, the stone-plastic substrate layer sheet, the lower material layer sheet and a second wear-resistant layer film, then carrying out a hot pressing process to obtain a finished product.

10. A method of manufacturing the stone-plastic hot-pressing flooring according to claim 9, wherein in the hot-pressing process, a pressure is controlled within a range of 3 to 6 MPa, a temperature is controlled within a range of 125 to 145°C, and a hot-pressing time is controlled within a range of 1,500 to 2,100 s.

11. A method of manufacturing the stone-plastic hot pressing flooring according to claim 9, 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.

12. A method of manufacturing the stone-plastic hot-pressing flooring according to claim 11, wherein in the first cold-pressing process, a pressure is controlled within a range of 5 to 8 MPa, a temperature is controlled within a range of 80 to 145°C, and a cold-pressing time is controlled within a range of 600 to 800 s.

13. A method of manufacturing the stone-plastic hot-pressing flooring according to claim 11, wherein in the second cold-pressing process, a pressure is regulated within a range of 8 to 15 MPa, a temperature is regulated within a range

14. from 23 to 80 °C and a cold pressing time is regulated in a range of 800 to 1000 s. A method of manufacturing the stone-plastic hot pressing floor covering according to claim 9, further comprising, after calendering the lower material layer intermediate, the middle material layer intermediate or the stone-plastic substrate layer, a slicing operation.