Semi-hard polypropylene floor and preparation method therefor

Abstract

Provided in the present invention are a semi-hard polypropylene floor and a preparation method therefor. The semi-hard polypropylene floor comprises a polypropylene wear-resistant layer, a polypropylene decorative layer, a polypropylene bonding layer, a polypropylene substrate layer and a polypropylene reinforcing layer, which are sequentially arranged from top to bottom, wherein the polypropylene bonding layer is prepared from a maleic-acid-modified polypropylene resin, and has a thickness of 0.05-0.2 mm; and the polypropylene reinforcing layer is prepared from modified polypropylene fibers. Since the polypropylene reinforcing layer of the present application is made of modified polypropylene fibers, not only can the toughness and strength of a product be improved, but also the product can be made to better fit the ground during paving, thereby ensuring the service life of the product; the semi-hard polypropylene floor does not need to be slotted, thereby saving on costs for fasteners; and in addition, since the polypropylene bonding layer has a thickness of 0.05-0.2 mm, the thickness of the polypropylene bonding layer is relatively small, thereby resulting in a relatively small usage amount of the maleic-acid-modified acrylic resin, and therefore the overall cost is relatively low.

Description

Semi-rigid polypropylene floor and preparation method thereof

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to the Chinese patent application with application number 202311126267.0 filed with the Patent Office of China on September 1, 2023, entitled "A semi-rigid polypropylene floor and its preparation method", the entire contents of which are incorporated by reference into this application. Technical Field

[0003] The present invention relates to the technical field of floor production, in particular to a semi-rigid polypropylene floor and a preparation method thereof. Background Art

[0004] Semi-rigid polyvinyl chloride (PVC) flooring is widely used due to its thinner thickness, greater flexibility, and lower price compared to rigid snap-lock PVC flooring. However, due to the halogen content in PVC resin, it can pose various health and environmental concerns during use. With the increasing demand for environmentally friendly flooring, there is an urgent need to develop a new, environmentally friendly, semi-rigid alternative to PVC flooring.

[0005] Polypropylene (PP) is a colorless, odorless, non-toxic, stable thermoplastic resin. It has low density, excellent chemical resistance, heat resistance and electrical insulation, as well as high strength mechanical properties and high wear resistance, and is widely studied and applied.

[0006] To achieve commercial success, semi-rigid flooring requires high filler (generally over 70%). However, due to the product's relatively thin thickness (generally under 3mm), it presents issues of fragility and insufficient strength. Currently, to improve the adhesion between the polypropylene resin and the decorative layer, maleic acid-modified polypropylene resin is often used as the primary resin component of the high-filler polypropylene substrate. However, due to the thickness of the polypropylene substrate, the amount of maleic acid-modified polypropylene resin required is relatively high, resulting in higher raw material costs.

[0007] Summary of the Invention

[0008] Based on this, the main purpose of the present invention is to provide a semi-rigid polypropylene floor and a preparation method thereof which can improve the toughness and strength of the product and has low raw material cost.

[0009] To achieve the above object, the present invention provides a semi-rigid polypropylene floor.

[0010] The semi-rigid polypropylene floor comprises a polypropylene wear-resistant layer, a polypropylene decorative layer, a polypropylene adhesive layer, a polypropylene base material layer, and a polypropylene reinforcement layer arranged in order from top to bottom;

[0011] The polypropylene adhesive layer is made of maleic acid modified polypropylene resin, and the thickness of the polypropylene adhesive layer is 0.05-0.2 mm;

[0012] The polypropylene reinforcement layer is made of modified polypropylene.

[0013] Preferably, the semi-rigid polypropylene floor further includes a polypropylene balancing layer, and the polypropylene balancing layer is located between the polypropylene base material layer and the polypropylene reinforcement layer.

[0014] Preferably, an anti-fouling, transparent, and scratch-resistant layer is provided on a side of the polypropylene decorative layer away from the polypropylene wear-resistant layer.

[0015] Preferably, the semi-rigid polypropylene floor comprises at least one of the following:

[0016] The anti-fouling, transparent, and scratch-resistant layer is obtained by coating a modified UV-curing transparent paint, and the coating amount of the modified UV-curing transparent paint is 15 to 30 g / m 2 ;

[0017] The polypropylene wear-resistant layer is made of high-transmittance and high-wear-resistant polypropylene resin, and the thickness of the polypropylene wear-resistant layer is 0.15 to 0.55 mm;

[0018] The polypropylene decorative layer is made of high-definition printed modified polypropylene resin, and the thickness of the polypropylene decorative layer is 0.07 to 0.15 mm;

[0019] The thickness of the polypropylene reinforcement layer is 0.1-0.3 mm.

[0020] Preferably, the polypropylene substrate layer has a thickness of 4 to 8 mm.

[0021] Preferably, the polypropylene substrate layer contains the following ingredients: 65-75 parts of inorganic filler, 15-25 parts of polypropylene resin, 1-5 parts of PE resin, 1-5 parts of toughening agent, 0.5-1 part of stabilizer, 0.2-0.5 part of compatibilizer, 0.02-0.05 part of antioxidant, and 0.2-1 part of lubricant.

[0022] Preferably, the semi-rigid polypropylene floor comprises at least one of the following:

[0023] The inorganic filler is one or more of silicon dioxide, calcium carbonate, aluminum oxide, zinc oxide, magnesium oxide, mica powder, and kaolin;

[0024] The polypropylene resin is one or more of isotactic polypropylene, syndiotactic polypropylene, and atactic polypropylene;

[0025] The PE resin is one or more of LDPE, LLDPE, and MDPE;

[0026] The toughening agent is one or more of POE, EVA, EPDM, and SBS;

[0027] The stabilizer is one or more of a hindered amine light stabilizer, a polyolefin light stabilizer, a benzophenone stabilizer, and a salicylic acid stabilizer;

[0028] The compatibilizer is one or more of MAH, EGMA, SM, 3200, and CA100;

[0029] The antioxidant is one or more of 326, 1010, 1076, and AO300;

[0030] The lubricant is one or more of paraffin, OA6, and stearic acid.

[0031] The present application also provides a method for preparing a semi-rigid polypropylene floor, which is used to prepare the above-mentioned semi-rigid polypropylene floor, comprising:

[0032] The polypropylene wear-resistant layer, the polypropylene decorative layer, the polypropylene adhesive layer, the polypropylene base material layer, and the polypropylene reinforcement layer are laminated by a hot pressing process to obtain a semi-finished floor. The hot pressing process temperature is 150-160° C., the hot pressing process pressure is 8-15 MPa, and the hot pressing process time is 20-40 minutes.

[0033] The semi-finished floor is subjected to tempering treatment, the tempering temperature is 70-95° C., and the tempering time is 2-5 minutes.

[0034] The semi-finished floor after tempering is punched and trimmed to obtain the required size, thereby obtaining the semi-rigid polypropylene floor.

[0035] Preferably, before tempering the semi-finished floor, the method further comprises:

[0036] After hot pressing, the semi-finished floor is coated with UV curing transparent paint by roller coating equipment and cured by UV light to obtain an anti-fouling, transparent and scratch-resistant layer. The coating amount is 15-30 g / m 2 , UV curing energy is 400~800mj / cm 2 .

[0037] Preferably, laminating the polypropylene wear-resistant layer, the polypropylene decorative layer, the polypropylene adhesive layer, the polypropylene base material layer, and the polypropylene reinforcement layer by a hot pressing process specifically includes:

[0038] A PET film, a polypropylene reinforcement layer, a polypropylene balancing layer, a polypropylene base layer, a polypropylene adhesive layer, a polypropylene decorative layer, a polypropylene wear-resistant layer, an anti-fouling transparent scratch-resistant layer, a PET film, an embossed plate, a PET film, an anti-fouling transparent scratch-resistant layer, a polypropylene wear-resistant layer, a polypropylene decorative layer, a polypropylene adhesive layer, a polypropylene base layer, a polypropylene balancing layer, a polypropylene reinforcement layer, and a PET film are stacked top to bottom and bonded by a hot pressing process to obtain a semi-finished floor; wherein the PET film is a low-light, high-transmittance PET film with a thickness of 0.1 to 0.15 mm; and the polypropylene balancing layer has a thickness of 0.1 to 0.5 mm.

[0039] Advantages of the technical solution of the present invention: The semi-rigid polypropylene floor of the present application includes a polypropylene wear-resistant layer, a polypropylene decorative layer, a polypropylene adhesive layer, a polypropylene base layer, and a polypropylene reinforcing layer arranged in sequence from top to bottom. The reinforcing layer is used to improve the toughness and strength of the product. Since the polypropylene reinforcing layer of the present application is a modified polypropylene, it can not only improve the toughness and strength of the product, but also improve the fit of the product to the ground when paved, thereby ensuring the service life of the product; in addition, since the polypropylene adhesive layer of the present application is made of maleic acid-modified polypropylene resin, the fit between the polypropylene resin and the decorative layer can be solved. Since the thickness of the polypropylene adhesive layer is 0.05-0.2 mm, the thickness of the polypropylene adhesive layer is relatively thin, so the amount of maleic acid-modified acrylic resin used is small, and thus the raw material cost and the overall cost are low. BRIEF DESCRIPTION OF THE DRAWINGS

[0040] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on the devices shown in these drawings without paying any creative work.

[0041] FIG1 is a schematic structural diagram of a semi-rigid polypropylene floor according to an embodiment;

[0042] Among them, 100, polypropylene wear-resistant layer; 200, polypropylene decorative layer; 300, polypropylene adhesive layer; 400, polypropylene base material layer; 500, polypropylene reinforcement layer; 600, polypropylene balance layer; 700, anti-fouling, transparent and scratch-resistant layer.

[0043] The purpose, features and advantages of the present invention will be further described with reference to the accompanying drawings and in conjunction with the embodiments. DETAILED DESCRIPTION

[0044] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. All other embodiments obtained by ordinary technicians in this field based on the embodiments of the present invention without making any creative efforts shall fall within the scope of protection of the present invention.

[0045] It should be noted that all directional indications (such as up, down, left, right, front, back, etc.) in the embodiments of the present invention are intended only to explain the relative positional relationships and movement of various components in a specific posture (as shown in the accompanying drawings). If the specific posture changes, the directional indications will also change accordingly. Furthermore, the terms "first," "second," etc., used in this invention are for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Therefore, features specified as "first" or "second" may explicitly or implicitly include at least one of these features. Furthermore, the term "and / or" throughout this text encompasses three solutions. For example, "A and / or B" includes solution A, solution B, and solutions where both A and B are satisfied. Furthermore, the technical solutions of various embodiments may be combined, but only if they are achievable by persons of ordinary skill in the art. If a combination of technical solutions contradicts or is unachievable, such combination shall be deemed non-existent and outside the scope of protection claimed by this invention.

[0046] As shown in Figure 1, the present application provides a semi-rigid polypropylene floor, which includes a polypropylene wear-resistant layer 100, a polypropylene decorative layer 200, a polypropylene adhesive layer 300, a polypropylene base layer 400, and a polypropylene reinforcement layer 500 arranged in sequence from top to bottom; the polypropylene adhesive layer 300 is made of maleic acid-modified polypropylene resin, and the thickness of the polypropylene adhesive layer 300 is 0.05-0.2mm; the polypropylene reinforcement layer 500 is made of modified polypropylene.

[0047] The semi-rigid polypropylene floor of the present application includes a polypropylene wear-resistant layer 100, a polypropylene decorative layer 200, a polypropylene adhesive layer 300, a polypropylene base layer 400, and a polypropylene reinforcement layer 500, which are arranged in order from top to bottom. The reinforcement layer is used to improve the toughness and strength of the product. Since the polypropylene reinforcement layer 500 of the present application is a modified polypropylene fiber, it can not only improve the toughness and strength of the product, but also improve the conformity of the product to the ground when paved, ensuring the service life of the product. In addition, since the polypropylene adhesive layer 300 of the present application is made of maleic acid-modified polypropylene resin, it can solve the conformity of the polypropylene resin to the decorative layer. Since the thickness of the polypropylene adhesive layer 300 is 0.05-0.2mm, the thickness of the polypropylene adhesive layer 300 is relatively thin, so the amount of maleic acid-modified acrylic resin used is small, and thus the raw material cost is low. The provision of the polypropylene reinforcement layer 500 makes the floor of the present application higher in strength, and the resulting semi-rigid polypropylene floor is obtained. The semi-rigid polypropylene floor does not require grooving, saving the cost of locking.

[0048] The specific steps of maleic acid modified polypropylene resin are as follows:

[0049] 80-120 parts of polypropylene resin, 3-5 parts of maleic anhydride, 0.3-0.8 parts of cumene peroxide and 0.4-0.6 parts of antioxidant 1010 are mixed evenly and melt-extruded at 190-230°C.

[0050] Specifically, the polypropylene reinforcement layer 500 can improve the fit of the product to the ground during paving, which means improving the adhesion between the product and the ground during the paving process. Because semi-rigid polypropylene flooring generally needs to be glued to the ground, if there is no polypropylene reinforcement layer 500, there will be a problem of insufficient adhesion between the semi-rigid polypropylene floor and the ground, which will lead to debonding during use.

[0051] Specifically, maleic acid modification is achieved by a special reaction to terminate maleic anhydride on the polypropylene molecular chain. Since the maleic acid molecular chain contains active groups, it can react with polar groups such as -NH2 and -OH to form good chemical bonds, thereby improving the adhesion between the polypropylene adhesive layer 300 and the decorative layer.

[0052] Specifically, the present application uses a special formula design to prepare a highly filled semi-rigid polypropylene floor with excellent flexibility without adding a plasticizer.

[0053] In this embodiment, the polypropylene wear-resistant layer 100 is made of a transparent material. Specifically, the polypropylene decorative layer 200 enhances the aesthetics of the product. The polypropylene wear-resistant layer 100 protects the polypropylene decorative layer 200. Furthermore, because the wear-resistant layer is made of a transparent material, the polypropylene wear-resistant layer 100 does not obscure the polypropylene decorative layer 200. Wear resistance is an important indicator of the floor's service life. Once the wear-resistant layer is damaged, the surface color pattern and overall structure of the polypropylene decorative layer 200 will be damaged, affecting its appearance and usability.

[0054] Furthermore, referring to Figure 1 , the semi-rigid polypropylene flooring also includes a polypropylene balancing layer 600, located between the polypropylene base layer 400 and the polypropylene reinforcement layer 500. The top surface of the polypropylene balancing layer 600 is connected to the polypropylene base layer 400, while the bottom surface of the polypropylene balancing layer 600 is connected to the polypropylene reinforcement layer 500. Specifically, the polypropylene decorative layer 200 and the polypropylene wear-resistant layer 100 on the polypropylene base layer 400 are composed of a filler-free polypropylene resin. Compared to the highly filled polypropylene base layer 400, they are more susceptible to deformation caused by temperature fluctuations and external forces, and are more susceptible to upward warping and deformation due to significant shrinkage. Adding a polypropylene balancing layer 600 between the polypropylene base layer 400 and the polypropylene reinforcement layer 500, below the top surface of the polypropylene balancing layer 600 and the connection between the polypropylene base layer 400 and the polypropylene reinforcement layer 500, can solve this problem. The polypropylene balancing layer 600 is designed to achieve a good stress balance with the polypropylene decorative layer 200 and polypropylene wear-resistant layer 100 above the polypropylene base layer 400, preventing product warping caused by the continuous contraction of the polypropylene decorative layer 200 and polypropylene wear-resistant layer 100 under external forces and temperature during use. The polypropylene balancing layer 600 is made of polypropylene resin with or without fillers. By adjusting the filler content and thickness, its thermal shrinkage can be adjusted to achieve shrinkage balance with the polypropylene decorative layer 200 and polypropylene wear-resistant layer 100 above the polypropylene base layer 400, thereby preventing product warping.

[0055] Furthermore, the components of the polypropylene balancing layer 600 are: inorganic filler accounts for 0-60%, and polypropylene resin accounts for 35-95%, wherein the polypropylene resin is the middle filling layer; the thickness of the polypropylene balancing layer 600 is 0.2-0.5 mm.

[0056] Furthermore, referring to FIG1 , a side of the polypropylene wear-resistant layer 100 away from the polypropylene decorative layer 200 is provided with an anti-fouling transparent scratch-resistant layer 700. Specifically, the anti-fouling transparent scratch-resistant layer 700 is intended to resist scratches on the surface of the product caused by sharp objects such as soles of shoes and sand and gravel on the corners of tables during daily use. Once the surface is scratched, it not only affects the appearance, but also easily becomes dirty and grime-infected. In this application, the polypropylene wear-resistant layer 100 and the anti-fouling transparent scratch-resistant layer 700 cooperate to better protect the product. Since the anti-fouling transparent scratch-resistant layer 700 is also transparent, neither the polypropylene wear-resistant layer 100 nor the anti-fouling transparent scratch-resistant layer 700 will block the polypropylene decorative layer 200.

[0057] Furthermore, the anti-fouling, transparent, and scratch-resistant layer 700 is coated with a modified UV-curing transparent paint, and the coating amount of the modified UV-curing transparent paint is 15 to 30 g / m 2 Specifically, it is difficult for an ordinary UV wear-resistant layer to form sufficient adhesion with the polypropylene wear-resistant layer 100. This problem can be solved by modifying the main components of the UV coating.

[0058] Furthermore, the thickness of the polypropylene base material layer 400 is 1.5-2.0 mm.

[0059] Furthermore, the polypropylene substrate layer 400 contains the following components: 65-75 parts of inorganic filler, 15-25 parts of polypropylene resin, 1-5 parts of PE resin, 1-5 parts of toughening agent, 0.5-1 parts of stabilizer, 0.2-0.5 parts of compatibilizer, 0.02-0.05 parts of antioxidant, and 0.2-1 parts of lubricant.

[0060] Specifically, the polypropylene resin is one or more of isotactic polypropylene, syndiotactic polypropylene, and atactic polypropylene, with a melt index of 5-15 g / 10 min, preferably a mixture of syndiotactic polypropylene and atactic polypropylene; the PE resin is one or more of LDPE, LLDPE, and MDPE, preferably LLDPE; the toughening agent is one or more of POE, EVA, EPDM, and SBS, preferably POE; the inorganic filler is one or more of silica, calcium carbonate, aluminum oxide, zinc oxide, magnesium oxide, mica powder, and kaolin, preferably calcium carbonate; the stabilizer is one or more of hindered amine light stabilizers, polyolefin light stabilizers, benzophenone stabilizers, and salicylic acid stabilizers, preferably polyolefin light stabilizers; the compatibilizer is one or more of MAH, EGMA, SM, 3200, and CA100, preferably MAH; the antioxidant is one or more of 326, 1010, 1076, and AO300, preferably A0300; the lubricant is one or more of paraffin, OA6, and stearic acid, preferably stearic acid. When all the above components are selected from the preferred embodiment, the obtained polypropylene substrate layer 400 has the best processing and mixing compatibility, stable discharge speed, minimum thickness deviation, and the best aging resistance.

[0061] Among them, LLDPE: Yangzi Petrochemical YLF-1801;

[0062] POE: Ecoson 3980, USA;

[0063] Calcium carbonate: Changzhou Rongao Chemical RA-1250;

[0064] Polyolefin light stabilizer: BASF 944;

[0065] MAH: Exxon US PO 1015;

[0066] Antioxidant: Nanjing Milan Chemical A0300;

[0067] Stearic acid: Jiangsu Jiaren Chemical Co., Ltd. 1842;

[0068] Furthermore, the polypropylene wear-resistant layer 100 is made of high-transmittance and high-wear-resistant polypropylene resin, and the thickness of the polypropylene wear-resistant layer 100 is 0.15 to 0.55 mm; specifically, the ordinary wear-resistant layer has slightly poor transmittance and wear resistance, and is not resistant to high temperatures (generally below 160°C). The polypropylene wear-resistant layer 100 made of high-transmittance and high-wear-resistant polypropylene resin has higher transparency, wear resistance improved by more than 10%, and can withstand high temperatures of 170°C.

[0069] Furthermore, the polypropylene decorative layer 200 is made of a modified polypropylene resin suitable for high-definition printing. The thickness of the polypropylene decorative layer 200 is 0.07 to 0.15 mm. Conventional decorative layers have low surface tension and poor wettability, making it difficult to print a good pattern and also offering slightly poor temperature resistance. The polypropylene decorative layer 200 made of modified polypropylene resin has improved surface wettability, enabling good pattern printing. It also improves the decorative layer's temperature resistance.

[0070] Furthermore, the polypropylene reinforcement layer 500 is made of modified polypropylene, and has a thickness of 0.1-0.3 mm. Specifically, the modified polypropylene reinforcement layer 500 not only has better toughness, but also improves its polarity, making it more conducive to bonding with the polypropylene balancing layer 600 above.

[0071] With reference to FIG1 , the present application further provides a method for preparing a semi-rigid polypropylene floor, which is used to prepare the above-mentioned semi-rigid polypropylene floor, comprising:

[0072] S100, laminating the polypropylene wear-resistant layer 100, the polypropylene decorative layer 200, the polypropylene adhesive layer 300, the polypropylene base material layer 400, and the polypropylene reinforcement layer 500 through a hot pressing process to obtain a semi-finished floor. The hot pressing process temperature is 150-160° C., the hot pressing process pressure is 8-15 MPa, and the hot pressing process time is 20-40 minutes.

[0073] S200, the semi-finished floor is tempered at a temperature of 70 to 95° C. for 2 to 5 minutes.

[0074] In S300, the tempered semi-finished flooring is punched and trimmed to the desired dimensions, resulting in a semi-rigid polypropylene floor. Specifically, punching and trimming are performed on the four edges of the flooring, similar to polishing, to ensure that the edges are straight and smooth, ensuring seamless assembly.

[0075] Furthermore, before the semi-finished floor is tempered, the following steps are further performed:

[0076] S101, coating the semi-finished floor after hot pressing with UV curing transparent paint by roller coating equipment, curing it by UV light irradiation to obtain an anti-fouling transparent scratch-resistant layer 700, with a coating amount of 15 to 30 g / m 2 , UV curing energy is 400~800mj / cm 2 Specifically, tempering treatment after roller coating of UV coating can effectively release the stress inside the product and help improve the dimensional stability of the product.

[0077] Furthermore, the polypropylene wear-resistant layer 100, the polypropylene decorative layer 200, the polypropylene adhesive layer 300, the polypropylene base material layer 400, and the polypropylene reinforcement layer 500 are laminated by a hot pressing process. Specifically,

[0078] A PET film, a polypropylene reinforcement layer 500, a polypropylene balancing layer 600, a polypropylene base layer 400, a polypropylene adhesive layer 300, a polypropylene decorative layer 200, a polypropylene wear-resistant layer 100, a PET film, an embossed plate, a PET film, a polypropylene wear-resistant layer 100, a polypropylene decorative layer 200, a polypropylene adhesive layer 300, a polypropylene base layer 400, a polypropylene balancing layer 600, a polypropylene reinforcement layer 500, and a PET film are stacked top to bottom and bonded through a hot pressing process to obtain a semi-finished floor; wherein the PET film is a low-light, high-transmittance PET film, and the thickness of the PET film is 0.1 to 0.15 mm.

[0079] Specifically, the PET film is an isolation film used to isolate the floor from the embossed board and prevent the floor from being pressed together with the embossed board;

[0080] Embossed boards are used to create a wood / stone-like concave and convex texture effect on the floor surface.

[0081] The embossed plate in this embodiment has textures on both sides, so that the present application presses two floor boards at a time, ensuring that textures are pressed out of both floor boards by the embossed plate, thereby improving the efficiency of preparing the floor boards.

[0082] Example

[0083] Specific method for preparing semi-rigid polypropylene floor:

[0084] A 2 mm thick polypropylene substrate layer 400 is provided.

[0085] The polypropylene substrate 400 is laminated to the upper and lower layers through a hot-pressing process. The stacking order, from top to bottom, is: PET film, polypropylene reinforcement layer 500, polypropylene balancing layer 600, highly filled polypropylene substrate layer 400, polypropylene adhesive layer 300, polypropylene decorative layer 200, polypropylene wear-resistant layer 100, anti-fouling, transparent, and scratch-resistant layer 700, PET film, embossed sheet, PET film, anti-fouling, transparent, and scratch-resistant layer 700, polypropylene wear-resistant layer 100, polypropylene decorative layer 200, polypropylene adhesive layer 300, highly filled polypropylene substrate layer 400, polypropylene balancing layer 600, polypropylene reinforcement layer 500, and PET film. The PET film is a low-light, high-transmittance PET film with a thickness of 0.1 mm. The hot-pressing temperature is 160°C, the pressure is 15 MPa, and the duration is 30 minutes.

[0086] After hot pressing, the laminated board is coated with UV coating by roller coating equipment and cured by UV light. The coating amount is 25g / m 2 , UV curing energy is 700mj / cm 2 .

[0087] After roller coating of UV coating, tempering is carried out at a tempering temperature of 85°C and a time of 2 minutes.

[0088] After tempering, semi-rigid polypropylene flooring is produced by punching and trimming.

[0089] The specific steps of modifying polypropylene resin with maleic acid are as follows:

[0090] 80-120 parts of polypropylene resin, 3-5 parts of maleic anhydride, 0.3-0.8 parts of cumene peroxide, and 0.4-0.6 parts of antioxidant 1010 are mixed evenly and melt-extruded at 200°C.

[0091] The polypropylene wear-resistant layer 100 is specifically isotactic PP, Hanwha Total FH44N; the polypropylene decorative layer 200 is specifically random PP, Hanwha Total RJ760.

[0092] The specific conditions for preparing the semi-rigid polypropylene floor in Examples 1 to 6 are shown in Table 1.

[0093] Table 1 Conditions for preparing various examples of semi-rigid polypropylene flooring

[0094] Comparative Example 1

[0095] Other preparation steps and preparation conditions are the same as those in Example 1, except that there is no polypropylene reinforcement layer 500.

[0096] Comparative Example 2

[0097] Other preparation steps and preparation conditions are the same as those in Example 1, except that there is no polypropylene balancing layer 600.

[0098] Comparative Example 3

[0099] Other preparation steps and preparation conditions are the same as those in Example 1, except that the anti-fouling transparent scratch-resistant layer 700 is obtained by coating a common UV wear-resistant layer (polyurethane acrylic resin).

[0100] Comparative Example 4

[0101] The other preparation steps and conditions are the same as those in Example 1, except that there is no polypropylene adhesive layer 300.

[0102] The hardness, toughness, high temperature resistance test, warpage change value after high temperature baking at 80°C*6h, and dimensional shrinkage of the floors prepared in Examples 1-6 and Comparative Examples 1-5 are shown in Table 2.

[0103] Table 2 Performance test results

[0104] As shown in Table 2, the polypropylene flooring of Examples 1-6 exhibits stable performance. However, in the comparative examples, Comparative Example 1 lacks the polypropylene reinforcement layer 500, resulting in low floor flexibility; Comparative Example 2 lacks the balancing layer 600, resulting in a significant change in floor warpage; Comparative Example 3, where the anti-fouling, transparent, and scratch-resistant layer 700 is coated with a conventional UV wear-resistant layer (polyurethane acrylic resin), exhibits low UV paint adhesion; and Comparative Example 4 lacks the polypropylene adhesive layer 300, resulting in low peel strength.

[0105] The semi-rigid polypropylene floor prepared by the preparation method of the semi-rigid polypropylene floor of the present application has a flat surface without bending, an overall thickness of 2.5mm, a hardness of 55D, a flexibility of 50mm, a peel strength of >6MPa, and after high-temperature baking at 80℃*6h, the warpage change value is ≤1.mm, and the dimensional shrinkage is ≤0.1%.

[0106] The above are only preferred embodiments of the present invention and are not intended to limit the patent scope of the present invention. All equivalent device transformations made using the contents of the present invention's description and drawings, or direct / indirect applications in other related technical fields within the inventive concept of the present invention are included in the patent protection scope of the present invention.

Claims

1. A semi-rigid polypropylene floor, characterized in that: It includes a polypropylene wear-resistant layer, a polypropylene decorative layer, a polypropylene adhesive layer, a polypropylene base material layer, and a polypropylene reinforcement layer which are sequentially arranged from top to bottom; The polypropylene adhesive layer is made of maleic acid modified polypropylene resin, and the thickness of the polypropylene adhesive layer is 0.05-0.2 mm; The polypropylene reinforcement layer is made of modified polypropylene.

2. The semi-rigid polypropylene floor as claimed in claim 1, characterized in that: The semi-rigid polypropylene floor further comprises a polypropylene balancing layer, and the polypropylene balancing layer is located between the polypropylene base material layer and the polypropylene reinforcement layer.

3. The semi-rigid polypropylene floor as claimed in claim 1, characterized in that: A stain-resistant, transparent, and scratch-resistant layer is disposed on a side of the polypropylene wear-resistant layer away from the polypropylene decorative layer.

4. The semi-rigid polypropylene floor as claimed in claim 3, characterized in that: At least one of the following: The anti-fouling, transparent and scratch-resistant layer is obtained by coating with a modified UV-curing transparent paint, and the coating amount of the modified UV-curing transparent paint is 15 to 30 g / m 2 ; The polypropylene wear-resistant layer is made of high-transmittance and high-wear-resistant polypropylene resin, and the thickness of the polypropylene wear-resistant layer is 0.15-0.55 mm; The polypropylene decorative layer is made of high-definition printed polypropylene resin, and the thickness of the polypropylene decorative layer is 0.07-0.15 mm; The thickness of the polypropylene reinforcement layer is 0.1-0.3 mm.

5. The semi-rigid polypropylene floor as claimed in claim 1, characterized in that: The thickness of the polypropylene substrate layer is 4 to 8 mm.

6. The semi-rigid polypropylene floor as claimed in claim 1, characterized in that: The polypropylene substrate layer comprises the following components: 65-75 parts of inorganic filler, 15-25 parts of polypropylene resin, 1-5 parts of PE resin, 1-5 parts of toughening agent, 0.5-1 parts of stabilizer, 0.2-0.5 parts of compatibilizer, 0.02-0.05 parts of antioxidant and 0.2-1 parts of lubricant.

7. The semi-rigid polypropylene floor as claimed in claim 6, characterized in that: Include at least one of the following: The inorganic filler is silicon dioxide, calcium carbonate, aluminum oxide, zinc oxide, magnesium oxide, mica powder, One or more of kaolin; The polypropylene resin is one or more of isotactic polypropylene, syndiotactic polypropylene and atactic polypropylene; The PE resin is one or more of LDPE, LLDPE and MDPE; The toughening agent is one or more of POE, EVA, EPDM, and SBS; The stabilizer is one or more of a hindered amine light stabilizer, a polyolefin light stabilizer, a benzophenone stabilizer, and a salicylic acid stabilizer; The compatibilizer is one or more of MAH, EGMA, SM, 3200, and CA100; The antioxidant is one or more of 326, 1010, 1076, and AO300; The lubricant is one or more of paraffin, OA6, and stearic acid.

8. A method for preparing a semi-rigid polypropylene floor, used for preparing the semi-rigid polypropylene floor according to any one of claims 1 to 7, characterized in that: include: The polypropylene wear-resistant layer, the polypropylene decorative layer, the polypropylene adhesive layer, the polypropylene base material layer and the polypropylene reinforcement layer are laminated by a hot pressing process to obtain a semi-finished floor, the temperature of the hot pressing process is 150-160° C., the pressure of the hot pressing process is 8-15 MPa, and the time of the hot pressing process is 20-40 minutes; The semi-finished floor is tempered at a temperature of 70 to 95° C. and for a time of 2 to 5 minutes. The semi-finished floor after tempering is punched and trimmed to obtain the required size, thereby obtaining the semi-rigid polypropylene floor.

9. The method for preparing a semi-rigid polypropylene floor according to claim 8, characterized in that: Before the semi-finished floor is tempered, the method further comprises: On the semi-finished floor after hot pressing, a UV curing transparent lacquer is applied by a roller coating device and cured by UV light irradiation to obtain an anti-fouling transparent scratch-resistant layer, and the coating amount is 15-30 g / m 2 , UV curing energy is 400~800mj / cm 2 .

10. The method for preparing a semi-rigid polypropylene floor according to claim 8, characterized in that: The polypropylene wear-resistant layer, the polypropylene decorative layer, the polypropylene adhesive layer, the polypropylene base material layer, and the polypropylene reinforcement layer are laminated by a hot pressing process, specifically including: PET film, polypropylene reinforcement layer, polypropylene balancing layer, propylene base layer, polypropylene bonding layer, polypropylene decorative layer, polypropylene wear-resistant layer, anti-fouling transparent scratch-resistant layer, PET film, embossed plate, PET film, anti-fouling transparent scratch-resistant layer, polypropylene wear-resistant layer, polypropylene decorative layer, polypropylene bonding layer, polypropylene The propylene base layer, the polypropylene balance layer, the polypropylene reinforcement layer and the PET film are stacked from top to bottom and bonded together through a hot pressing process to obtain a semi-finished floor; wherein the PET film is a low-light high-transmittance PET film, and the thickness of the PET film is 0.1 to 0.15 mm.

Images