Preparation method for fireproof, flame-retardant, wear-resistant, scratch-resistant and environmentally-friendly solid wood composite flooring

Abstract

The present invention relates to the technical field of wood artificial flooring processing, and relates to a preparation method for a fireproof, flame-retardant, wear-resistant, scratch-resistant and environmentally-friendly solid wood composite flooring. A solid wood composite flooring is a common wooden flooring. A multi-layer solid wood board is sturdy, moisture-resistant and less prone to deformation. The solid wood composite flooring is a flooring processed by taking a natural wood as a surface board and solid wood strips or a single board as a base material, and thus has the characteristics of the wood, i.e., comfortable walking experience, strong stability and highly natural visual appearance, and has good adaptability to underfloor heating. In the present invention, a coating is additionally arranged on the surface of a wear-resistant layer, so that the flooring has better wear resistance and scratch resistance; in the present invention, a modified vegetable glue is used in a base material board, so that the emission of formaldehyde is reduced; in addition, in the present invention, a modified antibacterial wax composite coating is used in a fully wax sealing process, which is more in line with the concept of environmental protection.

Description

Preparation method of fire-retardant, wear-resistant, scratch-resistant and environmentally friendly solid wood composite floor Technical Field

[0001] The invention belongs to the technical field of solid wood composite floors and relates to a method for preparing a fire-resistant, flame-retardant, wear-resistant, scratch-resistant and environment-friendly solid wood composite floor. Background Art

[0002] Engineered wood flooring is a common type of wood flooring. Its multi-layered solid wood planks are strong, moisture-resistant, and non-deformable. Engineered wood flooring uses natural wood as the topsheet and solid wood strips or veneer as the base. It inherits the characteristics of wood, including comfort, stability, a natural visual appeal, and good geothermal adaptability. Engineered wood flooring is constructed with multiple layers of plywood as the base, and a top layer of hardwood veneer or sliced ​​veneer, hot-pressed with glue. The base plywood must have an even number of layers, typically seven or nine, with a hardwood veneer as the top layer. Engineered wood flooring combines the wear resistance of laminate flooring with the deformation resistance of engineered wood flooring. It has proven to perform well in three harsh environments: public spaces, geothermal conditions, and humidity, earning it the nickname "multi-functional flooring" in the industry. Summary of the Invention

[0003] The purpose of the present invention is to provide a method for preparing a fire-resistant, flame-retardant, wear-resistant, scratch-resistant and environmentally friendly solid wood composite floor, which has better wear-resistant and scratch-resistant properties and better meets environmental protection requirements.

[0004] The purpose of the present invention can be achieved through the following technical solutions:

[0005] The structure of the floor includes a wear-resistant layer, a decorative layer, a base material layer and a balancing layer. The preparation process of the composite floor is as follows:

[0006] S1: Drying balance, using nitrogen to purge and dry each layer at 60 °C;

[0007] S2: Add a wear-resistant coating on the surface of the wear-resistant layer. The wear-resistant coating powder includes, by weight, 50-70 parts of silicon carbide, 20-30 parts of fumed nano-silicon dioxide, and 5-10 parts of a surfactant. The attachment process of the wear-resistant coating is as follows:

[0008] S21: The wear-resistant layer is mainly composed of aluminum oxide, a layer of cryolite powder is evenly covered on the surface of the aluminum oxide, and the aluminum oxide wear-resistant paper covered with cryolite powder is evenly heated at 1000 ℃ until it is semi-molten;

[0009] S22: spraying the mixed wear-resistant coating powder onto the surface of the semi-molten aluminum oxide wear-resistant paper by plasma method under nitrogen atmosphere, and after spraying evenly, purging the surface with nitrogen at a nitrogen flow rate of 20 m / s. While purging, the temperature is lowered to room temperature at a rate of 10°C / min;

[0010] S3: Pressing and laminating: Apply adhesive to each layer of the structure, first cold press at a pressure of 0.8-1.2 MPa for 15 minutes, then hot press at a pressure of 1-1.5 MPa for 7 minutes;

[0011] S4: Palletizing and curing: Place the prepared floor at 50℃ in a vacuum environment for 24 hours, and then place it at room temperature for 24 hours.

[0012] Furthermore, the surfactant in S2 is medium molecular weight PEG with a molecular weight of 10 3 -10 4 .

[0013] Furthermore, the plasma spraying parameters in S22 are: voltage 60~120 V, current 150~400 A, spraying distance 100~150 mm, and spraying rate 60~120 mm / s.

[0014] Furthermore, the base material layer of the solid wood composite floor is a multi-layer solid wood board, which is made of multi-layer plywood as the base and standard hardwood veneer panels or veneers as the panels, and is laminated. The preparation process of the base board is as follows: modified plant glue is applied between the multi-layer plywood, and the multi-layer plywood is pressed in a fixed mold with a hot press.

[0015] Furthermore, the plant gum modification steps are as follows: grinding the solid plant gum into particles with a particle size of 5-10 mm, placing the particles into a mixed solution of sodium hydroxide and sodium sulfite for reaction, filtering, spray-drying the filtrate to obtain sodium lignin sulfonate, reacting it with sodium carbonate for alkalization, and then reacting it with sodium bicarbonate for etherification, purifying, and drying to obtain a modified composite plant gum.

[0016] Plant extract glue is low in cost, non-toxic, can be evenly dispersed in water, and becomes a viscous colloid after expansion. Plant glue does not react with organic solvents. Using plant extract glue to bond multiple layers of plywood is in line with environmental protection concepts. The modified plant extract glue has better viscosity and can be applied more evenly on the board surface, thereby reducing the probability of thermal blistering in the laminated base board.

[0017] Furthermore, the pressure during the hot pressing of the plywood was 0.8~1.5 MPa and the temperature was 130 °C.

[0018] Furthermore, the single-sided adhesive coating amount in step S3 is 140-180 g / m 2 , cold pressing pressure 0.8~1.2 MPa, time 15 min, hot pressing pressure 1~1.5 MPa, time 7 min;

[0019] Furthermore, the adhesive is a mixture of melamine-modified urea-formaldehyde resin and red phosphorus in a molar ratio of 1:1. Adding red phosphorus flame retardant to the adhesive can improve the fire retardancy of the floor.

[0020] Silicon carbide has many excellent properties, such as high thermodynamic stability, good thermal conductivity, high electron mobility, oxidation resistance, corrosion resistance, and a thermal expansion coefficient similar to that of graphite. Plasma spraying is used to coat the surface of wear-resistant paper. This method has high production efficiency and is pollution-free. The spraying particle speed is high and the coating has high bonding strength. The ultra-high temperature characteristics facilitate the spraying of high-melting-point materials.

[0021] Furthermore, the floor uses full wax sealing technology to treat the floor interfaces, and the coating used is an antibacterial wax composite coating prepared by wrapping rare earth elements with green bio-wax.

[0022] Floor wax sealing technology is to process the floor interfaces during the production process so that the joints on all four sides of the floor are sealed with wax, thereby achieving the effect of waterproofing and moisture-proofing.

[0023] Furthermore, the preparation method of the composite coating is as follows: 0.35 wt% biowax and 0.75 wt% cerium group light rare earth element are dissolved in an anhydrous ethanol solution, cooled and ultrasonicated, and then 5 wt% antibacterial agent with an amino group is added to undergo a grafting reaction to obtain an antibacterial wax composite coating.

[0024] Applying a waxy composite coating to the floor joints creates a super-hydrophobic and antibacterial effect. The addition of rare earth elements also enhances the coating's corrosion resistance and improves its adhesion to the floor. This is because rare earth elements, as positive trivalent ions, are highly reactive, acting as active agents in the reaction and acting as catalysts themselves, forming strong chemical bonds with other molecules.

[0025] Beneficial effects of the present invention:

[0026] In the first aspect of the present invention, a layer of silicon carbide coating is attached to the aluminum oxide wear-resistant layer. The addition of the coating can improve the wear resistance and scratch resistance of the floor. In addition, silicon carbide has high thermodynamic stability and can improve the fire retardant performance of the floor.

[0027] In the second aspect of the present invention, modified plant-extracted glue is used to bond the multiple layers of plywood. The plant-extracted glue is low in cost and non-toxic, thereby improving the environmental friendliness of the product.

[0028] The third aspect of the present invention is to modify the coating used in the full wax sealing technology by adding rare earth elements to the original coating, thereby further improving the corrosion resistance of the coating and improving the adhesion of the coating. DETAILED DESCRIPTION

[0029] In order to further illustrate the technical means and effects adopted by the present invention to achieve the predetermined purpose of the invention, the present invention is further described in detail below with reference to the embodiments.

[0030] Example 1

[0031] The structure of the floor includes a wear-resistant layer, a decorative layer, a base material layer and a balancing layer. The preparation process of the composite floor is as follows:

[0032] S1: Drying balance, using nitrogen to purge and dry each layer at 60 °C;

[0033] S2: Add a wear-resistant coating on the surface of the wear-resistant layer. The wear-resistant coating powder includes, by weight, 70 parts of silicon carbide, 20 parts of fumed nano-silicon dioxide, and 10 parts of PEG-2000. The attachment process of the wear-resistant coating is as follows:

[0034] S21: The wear-resistant layer is mainly composed of aluminum oxide, a layer of cryolite powder is evenly covered on the surface of the aluminum oxide, and the aluminum oxide wear-resistant paper covered with cryolite powder is evenly heated at 1000 ℃ until it is semi-molten;

[0035] S22: The mixed wear-resistant coating powder was plasma sprayed on the surface of semi-molten aluminum oxide wear-resistant paper in a nitrogen atmosphere. The parameters were: voltage 60-120 V, current 150-400 A, spraying distance 100-150 mm, spraying rate 60-120 mm / s. After uniform spraying, the surface was purged with nitrogen at a nitrogen flow rate of 20 m / s. While purging, the temperature was lowered to room temperature at a rate of 10°C / min.

[0036] S3: Pressing and laminating, applying adhesive on each layer of the structure, with a single-sided adhesive coating of 160 g / m 2 , first cold pressing at 1.0 MPa for 15 min, then hot pressing at 1.5 MPa for 7 min;

[0037] S4: Palletizing and curing: Place the prepared floor at 50°C in a vacuum environment for 24 hours, and then place it at room temperature for 24 hours;

[0038] S5: The floor interface is sealed with wax, and the coating used is an antibacterial wax composite coating prepared by wrapping rare earth elements with green bio-wax.

[0039] The test results of this embodiment are shown in the following table:

[0040] Test item Unit Standard Specified value Test result Judgment result Immersion peeling performance - the cumulative length of debonding of any adhesive layer on each side does not exceed 1 / 3 of the length of the adhesive layer (less than 3mm is not counted) All 6 test pieces have no debonding and are qualified Static bending strength MPaX mean ≥30, X min ≥24X mean :61.8,X min :49.0Qualified Elastic modulus MPa≥35007070Qualified Moisture content%6.4~14.07.1Qualified Surface resistance to cold and hot cycles - no cracks, no bubblingNo cracks, no bubblingQualified Surface scratch resistance - 4.0N Surface decorative pattern is not scratched4.0N Surface decorative pattern is not scratchedQualified Surface wear resistance ≥40004500, no damaged points appear on the surface decorative layerQualified Surface crack resistance - Level 5 Level 5Qualified Surface pollution resistance - Level 5 Level 5Qualified Light fastness performance - ≥ Gray card level 4> Gray card level 4Qualified Formaldehyde emission mg / m 3 ≤0.0500.050 qualified

[0041] Comparative Example 1

[0042] The structure of the floor includes a wear-resistant layer, a decorative layer, a base material layer and a balancing layer. The preparation process of the composite floor is as follows:

[0043] S1: Drying balance, using nitrogen to purge and dry each layer at 60 °C;

[0044] S2: Add a wear-resistant coating on the surface of the wear-resistant layer. The wear-resistant coating powder includes, by weight, 70 parts of silicon carbide, 20 parts of fumed nano-silicon dioxide, and 10 parts of PEG-2000. The attachment process of the wear-resistant coating is as follows:

[0045] S21: The wear-resistant layer is mainly composed of aluminum oxide, a layer of cryolite powder is evenly covered on the surface of the aluminum oxide, and the aluminum oxide wear-resistant paper covered with cryolite powder is evenly heated at 1000 ℃ until it is semi-molten;

[0046] S22: The mixed wear-resistant coating powder was plasma sprayed on the surface of semi-molten aluminum oxide wear-resistant paper in a nitrogen atmosphere. The parameters were: voltage 60-120 V, current 150-400 A, spraying distance 100-150 mm, spraying rate 60-120 mm / s. After uniform spraying, the surface was purged with nitrogen at a nitrogen flow rate of 20 m / s. While purging, the temperature was lowered to room temperature at a rate of 10°C / min.

[0047] S3: Pressing and laminating, applying adhesive on each layer of the structure, with a single-sided adhesive coating of 160 g / m 2, first cold pressing at 1.0 MPa for 15 min, then hot pressing at 1.5 MPa for 7 min;

[0048] S4: Palletizing and curing: Place the prepared floor at 50°C in a vacuum environment for 24 hours, and then place it at room temperature for 24 hours;

[0049] S5: Wax sealing is performed on the floor interface. In this comparative example, ordinary paraffin wax is used for full wax sealing.

[0050] The test results of this comparative example are shown in the following table:

[0051] Test item Unit Standard Specified value Test result Judgment result Immersion peeling performance - the cumulative length of debonding of any layer of adhesive on each side does not exceed 1 / 3 of the length of the adhesive layer (less than 3mm is not counted) 5 test pieces have no debonding, and one test piece has slight debonding on the edge. Qualified Static bending strength MPaX mean ≥30, X min ≥24X mean :61.8,X min :49.0Qualified Elastic modulus MPa≥35007070Qualified Moisture content%6.4~14.07.1Qualified Surface resistance to cold and hot cycles - no cracks, no bubblingNo cracks, no bubblingQualified Surface scratch resistance - 4.0N Surface decorative pattern is not scratched4.0N Surface decorative pattern is not scratchedQualified Surface wear resistance ≥40004500, no damaged points appear on the surface decorative layerQualified Surface crack resistance - Level 5 Level 5Qualified Surface pollution resistance - Level 5 Level 5Qualified Light fastness performance - ≥ Gray card level 4> Gray card level 4Qualified Formaldehyde emission mg / m 3 ≤0.0500.050 qualified

[0052] The results show that the immersion and peeling performance of ordinary paraffin wax is lower than that of the modified antibacterial wax composite coating, and the edges are more prone to delamination.

[0053] Comparative Example 2

[0054] The structure of the floor includes a wear-resistant layer, a decorative layer, a base material layer and a balancing layer. The preparation process of the composite floor is as follows:

[0055] S1: Drying balance, using nitrogen to purge and dry each layer at 60 °C;

[0056] S2: This comparative example does not add a coating on the surface of the wear-resistant layer;

[0057] S3: Pressing and laminating, applying adhesive on each layer of the structure, with a single-sided adhesive coating of 160 g / m 2, first cold pressing at 1.0 MPa for 15 min, then hot pressing at 1.5 MPa for 7 min;

[0058] S4: Palletizing and curing: Place the prepared floor at 50°C in a vacuum environment for 24 hours, and then place it at room temperature for 24 hours;

[0059] S5: The floor interface is sealed with wax, and the coating used is an antibacterial wax composite coating prepared by wrapping rare earth elements with green bio-wax.

[0060] The test results of this comparative example are shown in the following table:

[0061] Test item Unit Standard Specified value Test result Judgment result Immersion peeling performance - the cumulative length of debonding of any adhesive layer on each side does not exceed 1 / 3 of the length of the adhesive layer (less than 3mm is not counted) All 6 test pieces have no debonding and are qualified Static bending strength MPaX mean ≥30, X min ≥24X mean :61.8,X min :49.0Qualified Elastic modulus MPa≥35007070Qualified Moisture content%6.4~14.07.1Qualified Surface resistance to cold and hot cycles - no cracks, no bubblingNo cracks, no bubblingQualified Surface scratch resistance - 4.0N Surface decorative pattern is not scratched4.0N Surface decorative pattern is not scratchedQualified Surface wear resistance ≥40004000, no damaged points appear on the surface decorative layerQualified Surface crack resistance - Level 5 Level 5Qualified Surface pollution resistance - Level 5 Level 5Qualified Light fastness performance - ≥Gray card level 4>Gray card level 4Qualified Formaldehyde emission mg / m 3 ≤0.0500.050 qualified

[0062] The results show that the surface wear resistance of the floor without adding coating on the wear-resistant layer is significantly reduced.

[0063] Comparative Example 3

[0064] The structure of the floor includes a wear-resistant layer, a decorative layer, a base material layer and a balancing layer. The preparation process of the composite floor is as follows:

[0065] S1: Drying balance, using nitrogen to purge and dry each layer at 60 °C;

[0066] S2: Add a wear-resistant coating on the surface of the wear-resistant layer. The wear-resistant coating powder includes, by weight, 70 parts of silicon carbide, 20 parts of fumed nano-silicon dioxide, and 10 parts of PEG-2000. The attachment process of the wear-resistant coating is as follows:

[0067] S21: The wear-resistant layer is mainly composed of aluminum oxide, a layer of cryolite powder is evenly covered on the surface of the aluminum oxide, and the aluminum oxide wear-resistant paper covered with cryolite powder is evenly heated at 1000 ℃ until it is semi-molten;

[0068] S22: The mixed wear-resistant coating powder was plasma sprayed on the surface of semi-molten aluminum oxide wear-resistant paper in a nitrogen atmosphere. The parameters were: voltage 60-120 V, current 150-400 A, spraying distance 100-150 mm, spraying rate 60-120 mm / s. After uniform spraying, the surface was purged with nitrogen at a nitrogen flow rate of 20 m / s. While purging, the temperature was lowered to room temperature at a rate of 10°C / min.

[0069] S3: Pressing and laminating, applying adhesive on each layer of the structure, with a single-sided adhesive coating of 160 g / m 2 , first cold pressing at 1.0 MPa for 15 min, then hot pressing at 1.5 MPa for 7 min;

[0070] S4: Palletizing and curing: Place the prepared floor at 50°C in a vacuum environment for 24 hours, and then place it at room temperature for 24 hours;

[0071] S5: The floor interface is sealed with wax, and the coating used is an antibacterial wax composite coating prepared by wrapping rare earth elements with green bio-wax.

[0072] In this comparative example, polyvinyl acetate was used to bond the multiple layers of plywood.

[0073] The test results of this comparative example are shown in the following table:

[0074] Test item Unit Standard Specified value Test result Judgment result Immersion peeling performance - the cumulative length of debonding of any adhesive layer on each side does not exceed 1 / 3 of the length of the adhesive layer (less than 3mm is not counted) All 6 test pieces have no debonding and are qualified Static bending strength MPaX mean ≥30, X min ≥24X mean :61.8,X min :49.0Qualified Elastic modulus MPa≥35007070Qualified Moisture content%6.4~14.07.1Qualified Surface resistance to cold and hot cycles - no cracks, no bubblingNo cracks, no bubblingQualified Surface scratch resistance - 4.0N Surface decorative pattern is not scratched4.0N Surface decorative pattern is not scratchedQualified Surface wear resistance ≥40004500, no damaged points appear on the surface decorative layerQualified Surface crack resistance - Level 5 Level 5Qualified Surface pollution resistance - Level 5 Level 5Qualified Light fastness performance - ≥ Gray card level 4> Gray card level 4Qualified Formaldehyde emission mg / m 3 ≤0.0500.053 unqualified

[0075] Through testing, the use of polyvinyl acetate has increased the formaldehyde emission of the floor

[0076] When the present invention is used:

[0077] The above description is merely a preferred embodiment of the present invention and does not constitute any form of limitation to the present invention. Although the present invention has been disclosed as above in terms of a preferred embodiment, it is not intended to limit the present invention. Any person skilled in the art can, without departing from the scope of the technical solution of the present invention, make some changes or modifications to equivalent embodiments using the technical contents disclosed above. However, any brief modifications, equivalent changes and modifications made to the above embodiments based on the technical essence of the present invention without departing from the content of the technical solution of the present invention are still within the scope of the technical solution of the present invention.

Claims

1. A preparation method of a fireproof, flame-retardant, wear-resistant, scratch-resistant and environmentally friendly solid wood composite floor. The structure of the floor includes a wear-resistant layer, a decorative layer, a substrate layer and a balance layer, characterized in that, Attach a wear-resistant coating on the surface of the wear-resistant layer. The preparation process of the composite floor is as follows: S1: Drying and equilibration. Blow-dry each layer structure with nitrogen at 60 °C. S2: Attach a wear-resistant coating on the surface of the wear-resistant layer. The wear-resistant coating includes, by weight, 50-70 parts of silicon carbide, 20-30 parts of gas-phase nano-silica, and 5-10 parts of surfactant. The attachment process of the wear-resistant coating is as follows. S21: The main component of the wear-resistant layer is aluminum oxide. Uniformly cover a layer of cryolite powder on the surface of aluminum oxide. Uniformly heat the aluminum oxide wear-resistant paper covered with cryolite powder at 1000 °C until it is in a semi-molten state. S22: Spray the mixed wear-resistant coating powder on the surface of the semi-molten aluminum oxide wear-resistant paper by plasma method under a nitrogen atmosphere. After spraying evenly, blow the surface with nitrogen. The nitrogen flow rate is 20 m / s. While blowing, lower the temperature to room temperature at a rate of 10 °C / min. S3: Press and laminate. Apply adhesive on each layer structure. First, perform cold pressing at a pressure of 0.8-1.2 MPa for 15 min, and then perform hot pressing at a pressure of 1-1.5 MPa for 7 min. S4: Stack and cure. Place the obtained floor in a vacuum environment at 50 °C for 24 h, and then place it in a normal temperature environment for 24 h.

2. The environmentally friendly solid wood composite floor with fire prevention, flame retardancy, wear resistance and scratch resistance according to claim 1, wherein, The surfactant in S2 is medium-molecular-weight PEG with a molecular weight of 10 3 -10 4 .

3. A fireproof, flame-retardant, wear-resistant, scratch-resistant and environmentally friendly solid wood composite floor according to claim 2, characterized in that, The plasma spraying parameters in S22 are: voltage 60-120 V, current 150-400 A, spraying distance 100-150 mm, spraying rate 60-120 mm / s.

4. A fireproof, flame-retardant, wear-resistant, scratch-resistant and environmentally friendly solid wood composite floor according to claim 1, characterized in that, In step S3, the adhesive used is a mixture of melamine-modified urea-formaldehyde resin glue MUF and red phosphorus with a molar ratio of 1:

1.

5. A fireproof, flame-retardant, wear-resistant, scratch-resistant and environmentally friendly solid wood composite floor according to claim 1, characterized in that, In step S3, the single-sided adhesive application amount of the adhesive is 140~180 g / m 2 .

6. A fireproof, flame-retardant, wear-resistant, scratch-resistant and environmentally friendly solid wood composite floor according to claim 1, characterized in that, The substrate layer of the solid wood composite floor is a multi-layer solid wood board. The preparation process of the base board is as follows: Apply the modified plant glue between multi-layer plywoods, and press the multi-layer plywoods in a fixed mold with a hot press.

7. A fireproof, flame-retardant, wear-resistant, scratch-resistant and environmentally friendly solid wood composite floor according to claim 6, characterized in that, The modification steps of the plant glue are as follows: Grind the solid plant glue into particles with a particle size of 5-10 mm. Put the particles into a mixed solution of sodium hydroxide and sodium sulfite for reaction, filter, spray-dry the filtrate to obtain sodium lignosulfonate, perform alkalization reaction with sodium carbonate, then perform etherification reaction with sodium bicarbonate, purify, and dry to obtain the modified composite plant glue.

8. A fireproof, flame-retardant, wear-resistant, scratch-resistant and environmentally friendly solid wood composite floor according to claim 6, characterized in that, During the hot pressing process of plywood, the pressure is 0.8-1.5 MPa and the temperature is 130 °C.

9. A fireproof, flame-retardant, wear-resistant, scratch-resistant and environmentally friendly solid wood composite floor according to claim 1, characterized in that, This floor uses a full wax-sealing technology to treat the floor joints. The coating used is an antibacterial wax composite coating prepared by wrapping rare earth elements with green biological wax.

10. A fireproof, flame-retardant, wear-resistant, scratch-resistant and environmentally friendly solid wood composite floor according to claim 9, characterized in that, The preparation method of the composite coating is as follows: Dissolve biological wax and cerium-group light rare earth elements in an anhydrous ethanol solution. After cooling and ultrasonic treatment, add an antibacterial agent with an amino group to carry out grafting reaction to obtain the antibacterial wax composite coating.