Ceramic tile-look stone plastic floor, and manufacturing method therefor

Abstract

The present invention belongs to the technical field of composite floors. Disclosed are a ceramic tile-look stone plastic floor and a manufacturing method therefor. The ceramic tile-look stone plastic floor comprises: from top to bottom, a wear-resistant layer, a decorative layer, a first rigid SPC substrate layer, a foamed SPC substrate layer and a second rigid SPC substrate layer. The components of the first rigid SPC substrate layer comprise 12-20 wt% of polyvinyl chloride resin (PVC), 12-20 wt% of organosilicon-modified acrylic resin, 50-70 wt% of calcium carbonate, and the balance being an auxiliary agent. The ceramic tile-look stone plastic floor is provided with grooves each extending downward from the top, the lowest point of each groove does not exceed half the thickness of the first rigid SPC substrate layer, and the grooves are used for simulating a grouting effect of ceramic tiles. By adding the organosilicon-modified acrylic resin to the rigid SPC substrate layers, the present application can effectively improve weather resistance, water resistance, wear resistance, stain resistance and other properties of rigid SPC substrate layers.

Description

A ceramic tile-like stone-plastic floor and its preparation method Technical Field

[0001] This invention belongs to the field of composite flooring technology, specifically relating to a ceramic tile-like stone-plastic flooring and its preparation method. Background Technology

[0002] With the development of building decoration materials, imitation marble tiles have become popular in the market due to their aesthetic appeal and durability. However, traditional imitation marble tiles are still ceramic tiles, and suffer from problems such as heavy weight, complex installation, and high cost. Furthermore, gaps will exist between adjacent tiles during installation, and the best current solution is to use grout. Grout is essentially an adhesive substance that combines various chemical components. Due to the difference in thermal expansion and contraction coefficients between grout and the tile itself, it can age and detach over time. Additionally, during tile installation, issues such as size and manual errors can cause unevenness between tiles.

[0003] Currently, there is a growing market demand for alternative materials that combine aesthetics, lightweight design, and ease of installation.

[0004] SPC flooring (Stone Plastic Composite) has attracted much attention as a new type of flooring material; it is a composite board made by mixing stone powder and thermoplastic polymer materials evenly and then extruding them at high temperature.

[0005] However, the surface decoration effect of SPC flooring is limited and cannot meet the needs of high-end decoration. Therefore, it is of great significance to develop a multi-layer co-extruded SPC flooring that combines the aesthetic effect of marble-look ceramic tiles with the advantages of SPC flooring. Summary of the Invention

[0006] The purpose of this invention is to overcome at least one deficiency of the prior art and to provide a ceramic tile-like stone plastic floor and its preparation method.

[0007] The technical solution adopted in this application is:

[0008] A ceramic tile-like stone plastic flooring, comprising, from top to bottom, a wear-resistant layer, a decorative layer, a first rigid SPC substrate layer, a foamed SPC substrate layer, and a second rigid SPC substrate layer.

[0009] The first rigid SPC substrate layer comprises 12-20 wt% polyvinyl chloride resin (PVC), 12-20 wt% silicone-modified acrylic resin, 50-70 wt% calcium carbonate, and the balance being additives and functional additives.

[0010] The imitation ceramic tile stone plastic flooring has grooves from top to bottom, and the lowest point of the grooves does not exceed half the thickness of the first rigid SPC substrate layer; the grooves are used to simulate the grouting effect of ceramic tiles.

[0011] In some embodiments, the second rigid SPC substrate layer comprises 12-20 wt% polyvinyl chloride resin (PVC), 12-20 wt% silicone-modified acrylic resin, 50-70 wt% calcium carbonate, and the balance being additives and functional additives.

[0012] In some embodiments, the first rigid SPC substrate layer and the second rigid SPC substrate layer comprise the following raw materials in parts by weight: 20-30 parts of polyvinyl chloride resin (PVC), 80-110 parts of calcium carbonate, 2-4 parts of calcium-zinc stabilizer, 2-4 parts of acrylate copolymer (ACR), 2-4 parts of toughening agent, 0.5-3 parts of internal lubricant, 0.5-3 parts of external lubricant, 0.1-0.5 parts of carbon black, and 20-30 parts of silicone-modified acrylic resin.

[0013] In some embodiments, the raw materials for preparing the silicone-modified acrylic resin include silicone monomers and epoxy acrylic resin, wherein the silicone monomers account for 10%-50% of the total mass of the silicone monomers and epoxy acrylic resin, preferably 20-40%, more preferably 30%-40%; and / or, the viscosity of the silicone-modified acrylic resin is 1000-2000 mPa·s.

[0014] In some embodiments, the texture of the decorative layer includes at least one of wood texture, marble texture, granite texture, fabric texture, carpet texture, cement texture, and metal texture; preferably, it is marble texture.

[0015] In some embodiments, the foamed SPC substrate layer comprises the following raw materials in parts by weight: 40-60 parts of polyvinyl chloride resin (PVC), 70-100 parts of calcium carbonate, 30-60 parts of recycled SPC foaming material, 3-5 parts of calcium-zinc stabilizer, 1-3 parts of acrylate copolymer (ACR), 5-10 parts of foaming regulator, 0.1-0.5 parts of yellow foaming agent, 0.1-0.3 parts of white foaming agent, 0.5-3 parts of internal lubricant, and 0.5-3 parts of external lubricant.

[0016] In some embodiments, a UV layer is disposed above the wear-resistant layer; and / or, a sound-absorbing layer is disposed below the second rigid SPC substrate layer.

[0017] In some embodiments, the thickness of the first rigid SPC substrate layer is 0.8-1.2 mm, the thickness of the foamed SPC substrate layer is 3.2-12.0 mm, and the thickness of the second rigid SPC substrate layer is 0.8-1.2 mm; and / or, the first rigid SPC substrate layer, the foamed SPC substrate layer, and the second rigid SPC substrate layer are prepared by a co-extrusion process.

[0018] In some embodiments, the grooves are created by planing.

[0019] In some embodiments, the width of the groove is 1.5mm-5mm, preferably 2-3mm.

[0020] A method for preparing ceramic tile-like stone-plastic flooring includes the following steps:

[0021] S1. Heat and mix the raw materials for the rigid SPC substrate layer; heat and mix the raw materials for the foamed SPC substrate layer;

[0022] S2. Transfer the raw materials for the rigid SPC substrate layer and the foamed SPC substrate layer to the extruder;

[0023] S3. Inject the foamed SPC substrate material into the mold through the central flow channel of the merging core; inject the rigid SPC substrate material into the mold through the side flow channel of the merging core, and co-extrude it through the distributor to form a rough plate with the upper layer being the first rigid SPC substrate layer, the middle layer being the foamed SPC substrate layer, and the lower layer being the second rigid SPC substrate layer.

[0024] S4. A decorative layer is provided on the first hard SPC substrate layer of the rough plate, and a wear-resistant layer is provided on the decorative layer.

[0025] S5. Apply a UV-curable transparent varnish to the wear-resistant layer to form a UV layer;

[0026] S6. The pattern is printed on the upper surface of the board by the printing roller;

[0027] S7. Planing to form a groove with a sealing effect, the planed part includes a UV layer, a wear-resistant layer, a decorative layer and part of the first hard SPC substrate layer, and the lowest point of the planing does not exceed half the thickness of the first hard SPC substrate layer.

[0028] The beneficial effects of this application are:

[0029] 1. Achieve lightweight design:

[0030] This application utilizes a co-extrusion process to obtain an ABA-type lightweight SPC substrate composed of a first rigid SPC substrate layer, a foamed SPC substrate layer, and a second rigid SPC substrate layer. This significantly reduces the weight of the flooring, lowers transportation and installation costs, and enhances the user experience. Conventional SPC flooring has a density of 1.9-2.1 g / cm³. 3 The density of the ABA-type SPC flooring in this application is 1.4-1.6 g / cm³. 3 This reduces weight by 20-30%.

[0031] 2. Enhance the decorative effect:

[0032] By using high-definition printing technology and a transparent wear-resistant layer, and through planing, a seamless grout finish is achieved, creating a realistic marble-like texture on SPC flooring to meet high-end decorative needs.

[0033] 3. By adding silicone-modified acrylic resin to the rigid SPC substrate layer, the weather resistance, water resistance, wear resistance and stain resistance of the rigid SPC substrate layer and the grout groove set in the layer can be effectively improved.

[0034] 4. Simplified installation process:

[0035] The snap-on installation design eliminates the need for auxiliary materials, simplifying the installation process and shortening the construction period.

[0036] 5. Enhance environmental friendliness:

[0037] Using recyclable and environmentally friendly materials reduces energy consumption in the production process and meets green building standards.

[0038] 6. Optimize overall performance:

[0039] By using multi-layer co-extrusion technology to obtain an ABA-type three-in-one SPC substrate layer, and tightly combining the decorative layer, SPC substrate layer and sound-absorbing layer, it provides high wear resistance, stain resistance, sound insulation and comfort, meeting the needs of high-end venues. Attached Figure Description

[0040] Figure 1 is a schematic diagram of the grout groove of the multi-layer co-extruded marble-look ceramic tile flooring of this application (one side of the planed groove).

[0041] Figure 2 is an enlarged view of the area marked by circle A in Figure 1.

[0042] Figure 3 is a schematic diagram of the grout groove of the multi-layer co-extruded marble-look ceramic tile flooring of this application (one side of the planed groove).

[0043] In the diagram: 1. UV layer; 2. Wear-resistant layer; 3. Decorative layer; 4. First rigid SPC substrate layer; 5. Foamed SPC substrate layer; 6. Second rigid SPC substrate layer; 7. Sound-absorbing layer (sound-absorbing pad). Detailed Implementation

[0044] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of this invention will be clearly and completely described below. Obviously, the described embodiments are only some embodiments of this invention, not all embodiments. Based on the embodiments of this invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this invention.

[0045] Where specific techniques or conditions are not specified in the examples, they shall be performed in accordance with the techniques or conditions described in the literature in this field, or in accordance with the product instructions. Reagents or instruments whose manufacturers are not specified are all conventional products that can be purchased through legitimate channels.

[0046] This application provides a ceramic tile-like stone plastic flooring with a grout-sealing effect. Stone plastic flooring (SPC flooring) is also known as Stone Plastic Composite Flooring or Stone Polymer Composite Flooring. Refer to Figures 1 and 2. Figure 1 includes a circled area marked "A," and Figure 2 is an enlarged view of the circled area in Figure 1. The ceramic tile-like stone plastic flooring includes, from top to bottom, a UV layer 1, a wear-resistant layer 2, a decorative layer 3, a first rigid SPC substrate layer 4, a foamed SPC substrate layer 5, a second rigid SPC substrate layer 6, and a sound-absorbing layer (sound-absorbing pad) 7.

[0047] The first rigid SPC substrate layer comprises 12-20 wt% polyvinyl chloride (PVC) powder, 12-20 wt% silicone-modified acrylic resin, 50-70 wt% calcium carbonate, and the remainder being additives and functional additives.

[0048] The imitation ceramic tile stone plastic flooring has grooves from top to bottom, and the lowest point of the grooves does not exceed half the thickness of the first rigid SPC substrate layer; the grooves are used to simulate the grouting effect of ceramic tiles.

[0049] In some embodiments, the second rigid SPC substrate layer comprises 12-20 wt% PVC resin powder, 12-20 wt% silicone-modified acrylic resin, 50-70 wt% calcium carbonate, and the balance being additives and functional additives.

[0050] In some embodiments, the first rigid SPC substrate layer and the second rigid SPC substrate layer comprise the following raw materials in parts by weight: 20-30 parts of polyvinyl chloride resin (PVC), 80-110 parts of calcium carbonate, 2-4 parts of calcium-zinc stabilizer, 2-4 parts of acrylate copolymer (ACR), 2-4 parts of toughening agent, 0.5-3 parts of internal lubricant, 0.5-3 parts of external lubricant, 0.1-0.5 parts of carbon black, and 20-30 parts of silicone-modified acrylic resin.

[0051] Preferably, the first rigid SPC substrate layer and the second rigid SPC substrate layer comprise the following raw materials in parts by weight: 22-28 parts of polyvinyl chloride resin (PVC), 95-110 parts of calcium carbonate, 3-4 parts of calcium-zinc stabilizer, 2.5-3.5 parts of acrylate copolymer (ACR), 2-3 parts of toughening agent, 0.5-2 parts of internal lubricant, 0.5-2 parts of external lubricant, 0.1-0.5 parts of carbon black, and 20-30 parts of silicone-modified acrylic resin.

[0052] In some embodiments, the raw materials for preparing the silicone-modified acrylic resin include silicone monomers and epoxy acrylic resin, wherein the silicone monomers account for 10%-50% of the total mass of the silicone monomers and epoxy acrylic resin, preferably 20%-40%, and more preferably 30%-40%.

[0053] In some embodiments, the viscosity of the silicone-modified acrylic resin is 1000-2000 mPa·s.

[0054] In some embodiments, the foamed SPC substrate layer comprises the following raw materials in parts by weight: 40-60 parts of polyvinyl chloride resin (PVC), 70-100 parts of calcium carbonate, 30-60 parts of recycled SPC foaming material, 3-5 parts of calcium-zinc stabilizer, 1-3 parts of acrylate copolymer (ACR), 5-10 parts of foaming regulator, 0.1-0.5 parts of yellow foaming agent, 0.1-0.3 parts of white foaming agent, 0.5-3 parts of internal lubricant, and 0.5-3 parts of external lubricant.

[0055] Preferably, the foamed SPC substrate layer comprises the following raw materials in parts by weight: 40-60 parts of polyvinyl chloride resin (PVC), 80-90 parts of calcium carbonate, 35-50 parts of recycled SPC foaming material, 3-5 parts of calcium-zinc stabilizer, 2-3 parts of acrylate copolymer (ACR), 5-8 parts of foaming regulator, 0.1-0.5 parts of yellow foaming agent, 0.1-0.3 parts of white foaming agent, 0.5-2 parts of internal lubricant, and 0.5-2 parts of external lubricant.

[0056] In some of these embodiments, the calcium carbonate has a particle size of 5-20 μm, preferably 5-15 μm.

[0057] In some embodiments, the texture of the decorative layer includes at least one of wood texture, marble texture, granite texture, fabric texture, carpet texture, cement texture, and metal texture; preferably, it is a marble texture. The decorative layer may be a decorative layer made of PVC film, or a decorative layer printed with high-definition ink or digitally printed.

[0058] In some embodiments, the wear-resistant layer is made of a highly transparent and highly wear-resistant modified polyvinyl chloride (PVC) resin.

[0059] In some embodiments, a UV layer is disposed above the wear-resistant layer. The UV layer is obtained by applying and curing a UV-curable transparent varnish, with the coating amount of the UV-curable transparent varnish being 15–30 g / m². 2 .

[0060] In some embodiments, the grooves are created by planing, preferably using a high-speed rotating tool. The lowest point of the planing does not exceed half the thickness of the first rigid SPC substrate layer. The resulting grooves are used to simulate the grouting effect of ceramic tiles.

[0061] In some embodiments, a sound-absorbing layer, or pad for sound absorption, is disposed beneath the second rigid SPC substrate layer (as shown in Figure 1). The main function of the sound-absorbing layer is to reduce noise from footsteps, furniture movement, and other floor activities. The sound-absorbing layer can generally be made of materials such as IXPE, EVA, or cork, and is bonded to the SPC substrate layer with adhesive.

[0062] In some embodiments, the thickness range of each layer in the multilayer co-extruded flooring of marble-look ceramic tile is as follows: UV layer 0.13-0.17mm, wear layer 0.3-0.7mm, decorative layer 0.05-0.09mm, first rigid SPC substrate layer 0.8-1.2mm, foamed SPC substrate layer 3.2-12.0mm, second rigid SPC substrate layer 0.8-1.2mm, and sound-absorbing pad 0.8-2.5mm.

[0063] In some embodiments, the width of the groove is 1.5mm-5mm, preferably 2-3mm.

[0064] A method for preparing ceramic tile-like stone-plastic flooring includes the following steps:

[0065] S1. Heat and mix the raw materials for the rigid SPC substrate layer; heat and mix the raw materials for the foamed SPC substrate layer;

[0066] S2. Transfer the rigid SPC substrate layer material and the foamed SPC substrate layer material to the extruder;

[0067] S3. Inject the foamed SPC substrate material into the mold through the central flow channel of the merging core; inject the rigid SPC substrate material into the mold through the side flow channel of the merging core, and co-extrude it through the distributor to form a rough plate with the upper layer being the first rigid SPC substrate layer, the middle layer being the foamed SPC substrate layer, and the lower layer being the second rigid SPC substrate layer.

[0068] S4. A decorative layer is provided on the first hard SPC substrate layer of the rough plate, and a wear-resistant layer is provided on the decorative layer.

[0069] S5. Apply a UV-curable transparent varnish to the wear-resistant layer to form a UV layer;

[0070] S6. The pattern is printed on the upper surface of the board by the printing roller;

[0071] S7. Planing to form a groove with a sealing effect, the planed part includes a UV layer, a wear-resistant layer, a decorative layer and part of the first hard SPC substrate layer, and the lowest point of the planing does not exceed half the thickness of the first hard SPC substrate layer.

[0072] In some embodiments, before planing the groove in step S7, the edges of the sheet material need to be grooved to form a special structure that facilitates assembly. This could be a straight groove, a locking groove, or a similar structure. A locking structure is preferred.

[0073] The present application will be further described below with reference to embodiments, but is not limited thereto.

[0074] Example 1

[0075] 1. A formula for foamed multilayer flooring:

[0076] 1.1 Rigid SPC substrate layer: includes a first rigid SPC substrate layer and a second rigid SPC substrate layer, which are equivalent to two surface layers, sandwiching the foamed SPC substrate layer (core layer) to form an ABA-type structure.

[0077] The rigid SPC substrate (surface layer) comprises the following raw materials in parts by weight: 25 parts PVC resin powder, 100 parts heavy calcium carbonate, 3.6 parts calcium-zinc stabilizer, 3 parts ACR processing aid, 1 part internal lubricant, 0.8 parts external lubricant, 2.2 parts toughening agent, 0.3 parts carbon black, and 25 parts silicone-modified acrylic resin.

[0078] The selected PVC powder is conventional SG5 powder.

[0079] The selected calcium carbonate powder has a particle size of 400 mesh. Too coarse particles will cause the product to scorch easily, while too fine particles will increase the cost and make the product too brittle.

[0080] Preferably, ordinary SPC recycled material can also be used in part, which can reduce costs and increase efficiency. Ordinary SPC recycled material is the crushed material of SPC flooring, which contains some PVC resin and other components. The recycled material component is a "concentration" relative to the other components.

[0081] The selected calcium-zinc stabilizer is a non-toxic and environmentally friendly PVC calcium-zinc stabilizer, which is composed of zinc soap, calcium soap, auxiliary stabilizers, lubricants, etc. It has the characteristics of being non-toxic, highly efficient, stable, producing fine foam cells, excellent demolding performance, excellent processing performance, and long production cycle.

[0082] The selected foaming processing aid is an acrylate copolymer (ACR), which is a copolymer of MMA (methyl methacrylate) and acrylates. ACR can promote the plasticizing properties of PVCU during processing and improve its flowability.

[0083] The selected internal lubricant is G60, which is a lubricant whose main components include stearic acid, etc.

[0084] The toughening agent used is modified CPVC resin particles.

[0085] The selected silicone-modified acrylic resin is prepared as follows:

[0086] The industrial preparation methods for silicone-modified epoxy acrylate resins typically involve chemical reactions and process optimization to ensure product performance stability and the feasibility of large-scale production. The following are common industrial preparation methods and their key steps:

[0087] 1) Add 70 parts of epoxy acrylic resin (as the main resin, providing mechanical strength, adhesion and curing performance), 30 parts of organosilicon monomer (such as γ-glycidyl etheroxypropyltrimethoxysilane), and appropriate amounts of solvent (such as toluene, acetone, methyl ethyl ketone, etc.) to the reaction vessel.

[0088] Add a catalyst (to promote the reaction between organosilicon and epoxy acrylate resin, such as an acidic or basic catalyst, preferably tetramethylammonium hydroxide).

[0089] 2) Heat the reactor to 80-100℃ and stir for 4-6 hours. Monitor the viscosity (1000-50000mPa·s(25℃)) and epoxy value of the reaction system (the epoxy value may decrease to 0.2-0.4eq / 100g after modification).

[0090] 3) Cool down to below 50℃, filter to remove impurities, and add a suitable solvent (such as toluene, acetone, methyl ethyl ketone, etc.) to adjust the viscosity (set at 1000-2000 mPa·s).

[0091] 4) Pack the finished product into a sealed container and store it in a cool, dry place.

[0092] Those skilled in the art can also purchase the corresponding silicone-modified epoxy acrylate resin as a raw material.

[0093] The carbon black used serves to color the board.

[0094] 1.2 The foamed SPC substrate layer (core layer) comprises the following raw materials in parts by weight: 50 parts PVC resin powder, 80 parts 1250 mesh calcium carbonate, 38 parts recycled SPC foaming material, 4.5 parts calcium-zinc stabilizer, 2.5 parts ACR processing aid, 6 parts foaming regulator, 0.25 parts yellow foaming agent, 0.1 parts white foaming agent, 0.95 parts internal lubricant, and 0.8 parts external lubricant.

[0095] The selected PVC powder is conventional SG8 powder, because the core layer is used for foaming. SG-8 PVC resin powder has a degree of polymerization of 650-740 and a K value of 55-59, which is more suitable for foaming.

[0096] The selected calcium carbonate powder is 1250 mesh. When the particle size of calcium carbonate is matched with the foaming agent, it can act as a nucleating agent, thereby promoting foaming. Appropriate calcium carbonate particle size, without agglomeration, allows for better adsorption of foaming gas to form bubble nuclei, controlling the number of bubbles and resulting in finer bubbles.

[0097] a. First, calcium carbonate can act as a nucleating agent, adsorbing foaming gases to form bubble nuclei, controlling the number of bubbles, and making the bubbles finer; b. Improves melt properties: Calcium carbonate itself has high rigidity, which can slow down melt deformation and movement, thereby inhibiting excessively rapid bubble expansion; c. Controls finer bubble size. If the calcium carbonate particle size is greater than 20 μm, or too fine (e.g., less than 5 μm) causing self-agglomeration, it will affect the foaming effect.

[0098] The selected recycled SPC foam material is pulverized material from SPC foam boards. The recycled material composition is a "concentration" relative to other components. This recycled SPC foam material contains residual foaming agent that can be used. In addition, the recycled SPC foam material itself has a relatively low density, which helps to reduce the density of the foamed SPC substrate layer (core layer).

[0099] In some embodiments, the density of the foamed SPC substrate layer (core layer) is typically 1.1-1.3 g / cm³. 3 .

[0100] The selected calcium-zinc stabilizer is a non-toxic and environmentally friendly PVC calcium-zinc stabilizer, which is composed of zinc soap, calcium soap, auxiliary stabilizers, lubricants, etc. It has the characteristics of being non-toxic, highly efficient, stable, producing fine foam cells, excellent demolding performance, excellent processing performance, and long production cycle.

[0101] The selected foaming processing aid is an acrylate copolymer (ACR), which is a copolymer of MMA and acrylates. ACR can promote the plasticizing properties of PVCU during processing and improve its flowability.

[0102] The selected internal lubricant is G60, which is a lubricant whose main components include stearic acid, etc.

[0103] The selected external lubricant is PE wax.

[0104] The foaming regulator used is actually an acrylate processing aid.

[0105] The selected yellow foaming agent has a gas emission rate of 220-230 ml / g, a decomposition temperature of 195-205℃, and a volatility of ≤0.2% (110℃ 1H).

[0106] The selected white foaming agent has a gas emission rate of 130-140 ml / g, a decomposition temperature of 157-165℃, and a volatility of ≤0.5% (110℃ 1H).

[0107] 2. An extrusion process for a multi-layer co-extruded PVC flooring substrate with a sealant effect, comprising the following steps:

[0108] 2.1 Rigid SPC substrate layer (surface layer) and foamed SPC substrate layer (core layer) are prepared in different reactors. Specifically, according to the above formula, calcium carbonate and PVC powder are added together to a high-speed mixer, and then plasticizers (such as ACR processing aids), stabilizers, lubricants and other additives are added. The mixture is stirred and heated to 110-120℃ before being discharged and cooled.

[0109] 2.2 When the mixture from 2.1 is cooled to 65°C, it is placed into the storage silo, and the mixture in the storage silo is conveyed to the screw extruder through the screw feeding system.

[0110] 2.3 A rigid SPC (surface layer) structural substrate is prepared using a twin-screw extruder, wherein the surface layer material formulation is as described in the surface layer extrusion formulation design above. A foamed SPC (core layer) structural substrate is prepared using a single-screw extruder, wherein the core layer material formulation is as described in the core layer extrusion formulation design above.

[0111] 2.4 The foamed SPC substrate material is injected into the mold through the central flow channel of the confluence core; the rigid SPC substrate material is injected into the mold through the side flow channel of the confluence core, and co-extruded through a distributor to form a rough plate with the upper layer being the first rigid SPC substrate layer, the middle layer being the foamed SPC substrate layer, and the lower layer being the second rigid SPC substrate layer.

[0112] 2.4.1 Extrusion Section

[0113] 2.4.1.1 Equipment heating / precooling.

[0114] 2.4.1.1.1 Set the mold opening temperature (170~180℃), mold temperature (180~190℃), and side plate temperature (190~210℃).

[0115] 2.4.1.1.2 Set the distributor temperature, which should be adjusted appropriately to ensure stable product extrusion, and turn on the heating for about 0.5 hours.

[0116] 2.4.1.1.3 Set the temperature of the mold rollers (190℃ for roller 1, 190℃ for roller 2, 180℃ for roller 3, and cold water rollers for rollers 4 and 5). It is permissible and should be adjusted appropriately while ensuring stable extrusion of the product. Turn on the heating for about 1.5 hours.

[0117] 2.4.1.1.4 Set the shaping cooling roller and confirm that the cooling water is circulating at around 15°C.

[0118] 2.4.1.2 Powering on

[0119] 2.4.1.2.1 Start the screw compressor.

[0120] 2.4.1.2.1.1 Set the speed of the 80# auxiliary machine to 200 R / min and the feeding speed to 120 R / min.

[0121] 2.4.1.2.1.2 After the 80# auxiliary machine discharges material, set the speed of the 92# main machine to 200 R / min and the feeding speed to 90 R / min.

[0122] 2.4.1.2.1.3 Slowly increase the rotation speed multiple times, with each increase being 20-40 R / min.

[0123] 2.4.1.2.1.4 Set the stable rotation speed, feeding speed and current, and allow and should adjust them appropriately while ensuring stable product extrusion.

[0124] 2.4.1.2.1.5 Taking the production of 6.5mm products as an example, set the speed of each roller as a reference.

[0125] 2.4.1.2.1.6 Reference for setting traction, bracket and lamp cover.

[0126] 2.4.1.3 Discharge pull plate.

[0127] 2.4.1.3.1 Move the machine platform and bring the mold roller close to the extrusion die to prepare for plate pulling.

[0128] 2.4.1.3.2 After the extruded plate comes out of the die, it is manually pulled onto the cooling and shaping pressure roller for transfer.

[0129] 2.4.1.3.3 After confirming the flatness of the extruded plate and the thickness of each layer, turn on the lampshade and perform heating and lamination. The film is a PVC colored film, and various patterns can be selected as the base color. Here, a gray stone-textured PVC colored film is used. A wear-resistant layer is then further laminated.

[0130] 2.4.1.3.4 Cut the edges by adjusting the spacing of the rotary cutters according to the required width of the laminated board.

[0131] 2.4.1.3.5 After passing through the cooling zone, the laminated board is cut into the required size using a shearing machine. Common sizes are 1800*970mm, 1500*970mm, or 1200*970mm. In this embodiment, 1500*970mm is used.

[0132] 2.4.1.3.6 Apply a UV-cured transparent varnish to the wear-resistant layer of the board to form a UV layer.

[0133] 2.4.1.3.7 The pattern is printed on the upper surface of the board by the printing roller.

[0134] 2.4.1.3.8 After sawing, the large board is cut into smaller pieces: from 1500*970mm to 1500*225mm.

[0135] 2.5 Grooving

[0136] 2.5.1 Grooving is performed on the edges of the board as required. A CNC milling machine or a locking grooving machine is used to groove the four sides of the 1500*225mm board. The two sides of the long side are male and female grooves, and the two sides of the short side are male and female grooves.

[0137] The specific operation is as follows: A male groove (raised structure) is machined on one side of the long side (1500mm) of the board, and a female groove (recessed structure) is machined on the other side for splicing along the long side. A male groove (raised structure) is machined on one side of the short side (225mm) of the board, and a female groove (recessed structure) is machined on the other side for splicing along the short side. This allows adjacent boards to be tightly connected through the interlocking splicing of the male and female grooves.

[0138] Male groove (convex groove): The width is 0.1-0.2mm smaller than the female groove (to reserve assembly clearance), and the depth matches the female groove (usually 1 / 3-1 / 2 of the plate thickness).

[0139] Female groove (recess): Width = Male groove width + gap, depth is the same as male groove.

[0140] 2.5.2 Grooves (planing) are made on the upper surface edge areas of two adjacent sides of each board. The planing depth is designed to be 0.6-1.0mm and the width is 2-3mm. High-speed rotating cutters are used to process the grooves to form grooves with a sealing effect.

[0141] For example, a piece of flooring that has been cut to the required size is divided into four sides: 1, 2, 3, and 4. Marking them clockwise, all sides 1 and 2 are planed to remove the UV layer, wear layer, decorative layer, and part of the first hard SPC substrate layer, forming grooves. This way, the spliced ​​flooring will have a seamless appearance on each side.

[0142] The results are shown in Figures 1 and 3. Figure 1 shows that a groove is formed on one side of the male groove, while the opposite female groove of the same board is left untreated to maintain its original flat state. Adjacent boards are spliced ​​together through the male and female grooves to obtain a groove with a sealing effect, with a depth of 0.6-1.0mm and a width of 2-3mm.

[0143] Figure 3 shows that a groove is formed on one side of the female groove, while the opposite male groove of the same board is left untreated to maintain its original flat state. Adjacent boards are spliced ​​together through the male and female grooves to obtain a groove with a sealing effect, a depth of 0.6-1.0mm and a width of 2-3mm.

[0144] In addition, grooves can be cut into other parts of the board according to the design to create grooves that simulate the effect of tile grout.

[0145] In this embodiment, the thickness of each layer in the multi-layer co-extruded flooring of the marble-look ceramic tile is as follows: UV layer is 0.15mm, wear layer is 0.3mm, decorative layer is 0.07mm, first rigid SPC substrate layer is 0.8-1.0mm, foamed SPC substrate layer is 3.2-3.5mm, second rigid SPC substrate layer is 0.8-1.0mm, and sound absorption pad is 1-2mm.

[0146] The UV layer (0.15mm), wear-resistant layer (0.3mm), decorative layer (0.07mm), and a portion of the first hard SPC substrate layer (approximately 0.1-0.4mm) are planed away to form a groove with a depth of approximately 0.6-1.0mm, used to simulate the effect of a grout sealant.

[0147] The planing depth is determined by ensuring that the lowest point of the groove does not exceed half of the solid first hard SPC substrate layer.

[0148] 2.5.4 The assembled result presents a marble-like appearance with grout lines. The grout line dimensions can be adjusted according to customer needs.

[0149] Example 2

[0150] 1. A formula for foamed multi-layer flooring with a sealant effect:

[0151] The rigid SPC substrate layer (surface layer) comprises the following raw materials in parts by weight: 25 parts PVC resin powder, 110 parts heavy calcium carbonate, 3 parts calcium-zinc stabilizer, 3 parts ACR foaming processing aid, 1 part internal lubricant, 0.8 parts external lubricant, 2.2 parts toughening agent, 0.3 parts carbon black, and 20 parts silicone-modified acrylic resin.

[0152] The foamed SPC substrate layer (core layer) comprises the following raw materials in parts by weight: 45 parts PVC resin powder, 80 parts calcium carbonate, 40 parts recycled SPC foaming material, 3.5 parts calcium-zinc stabilizer, 2.5 parts ACR foaming processing aid, 0.95 parts internal lubricant, 0.8 parts external lubricant, 6 parts foaming regulator, 0.25 parts yellow foaming agent, and 0.1 parts white foaming agent.

[0153] 2. The preparation method is the same as in Example 1, and a foamed multilayer floor with a sealant effect is obtained.

[0154] Example 3

[0155] 1. A formula for foamed multi-layer flooring with a sealant effect:

[0156] The rigid SPC substrate layer (top layer) comprises the following raw materials in parts by weight: 25 parts PVC resin powder, 95 parts heavy calcium carbonate, 3.6 parts calcium zinc stabilizer, 3 parts ACR foaming processing aid, 1 part internal lubricant, 0.8 parts external lubricant, 2.2 parts toughening agent, 0.3 parts carbon black, and 30 parts silicone-modified acrylic resin.

[0157] The foamed SPC substrate layer (core layer) comprises the following raw materials in parts by weight: 55 parts PVC resin powder, 80 parts calcium carbonate, 35 parts recycled SPC foaming material, 4 parts calcium-zinc stabilizer, 2.5 parts ACR foaming processing aid, 0.95 parts internal lubricant, 0.8 parts external lubricant, 6 parts foaming regulator, 0.25 parts yellow foaming agent, and 0.1 parts white foaming agent.

[0158] 2. The preparation method is the same as in Example 1, and a foamed multilayer floor with a sealant effect is obtained.

[0159] Example 4

[0160] The formula is the same as in Example 1. The preparation method is the same as in Example 1 except that the location of the grout opening is different.

[0161] The steps for grooving are as follows:

[0162] 2.5 Grooving

[0163] 2.5.1 Grooving is performed on the edges of the boards as required. A male groove (raised structure) is machined on one side of the long side (1500mm), and a female groove (recessed structure) is machined on the other side for splicing along the long side. A male groove (raised structure) is machined on one side of the short side (225mm), and a female groove (recessed structure) is machined on the other side for splicing along the short side. This interlocking splicing of adjacent boards through the male and female grooves achieves a tight connection.

[0164] 2.5.2 On each 1500*225mm board, a through groove is machined along the center line of its length direction. The starting point and ending point of the through groove are located at the midpoint of the two long sides (1500mm). The planing depth is designed to be 0.6-1.0mm and the width is 2-3mm. The machining is carried out using a high-speed rotating tool to form a groove with a sealing effect.

[0165] Compare with Example 1

[0166] 1. Standard flooring formula:

[0167] Its base material consists of 75 parts PVC resin powder, 250 parts heavy calcium carbonate, 7 parts stabilizer, 0.7 parts external lubricant PE wax, and 1.7 parts internal lubricant CA80.

[0168] The selected PVC powder is conventional SG5 powder.

[0169] The selected calcium carbonate powder is 400 mesh. Too coarse particles will cause the product to scorch easily, while too fine particles will increase the cost and make the product too brittle.

[0170] The selected stabilizer is a calcium-zinc stabilizer.

[0171] The selected internal lubricant is stearic acid.

[0172] The selected external lubricant is PE wax.

[0173] 2. The extrusion process of this substrate, its characteristics, and the selection of the backing film include the following steps:

[0174] 2.1 Add 400-mesh heavy calcium carbonate, PVC powder, and some recycled material to a high-speed mixer, along with stabilizer and lubricant. Mix and heat to 110-120℃, then discharge and cool.

[0175] 2.2 When the mixture from 2.1 is cooled to 65°C, it is placed into the storage silo. The mixture in the storage silo is then conveyed to the twin-screw extruder (a conical twin-screw extruder) through a screw feeding system.

[0176] 2.3 The barrel temperature is controlled at 160-180℃, the die temperature at 200-220℃, and the die outlet cooling temperature at 100-140℃. After extrusion, the material is shaped by the die, then calendered by rollers 1 and 2 to adjust the thickness and shape. Roller 3 applies a colored film (stone-patterned film) and a wear-resistant layer. Rollers 4 and 5 emboss (marble pattern). After cooling, the material is cut to obtain a sheet with a size of 1500*970mm. Further sawing is performed, reducing the sheet size from 1500*970mm to 1500*225mm.

[0177] 2.4 Grooving

[0178] 2.4.1 Grooving shall be performed as required. A male groove (raised structure) shall be machined on one side of the long side (1500mm), and a female groove (recessed structure) on the other side, for splicing along the long side. A male groove (raised structure) shall be machined on one side of the short side (225mm), and a female groove (recessed structure) on the other side, for splicing along the short side. This ensures a tight connection between adjacent panels through the interlocking splicing of the male and female grooves.

[0179] 2.4.2 Grooving (planing) is performed on the upper surface edge areas of two adjacent sides of each sheet of material using a high-speed rotating tool.

[0180] For example, a piece of flooring already cut to the required size is divided into four sides: 1, 2, 3, and 4. Marking them clockwise, all sides 1 and 2 are planed. Because the substrate layer in this comparative example is a single layer, during the planing process, the entire part above the substrate layer is planed off, and then a small portion of the substrate layer is removed. The planing depth of the substrate layer is approximately 0.1-0.4mm, and the width is 2-3mm, resulting in grooves that simulate the effect of tile grout.

[0181] Compare with Example 2

[0182] 1. Conventional cold-laid multi-layer flooring:

[0183] Its base material consists of 400 parts PVC resin powder, 1700 parts calcium carbonate, 150 parts DOTP oil, 7 parts stabilizer, and 3 parts carbon black.

[0184] The selected PVC powder is conventional SG5 powder.

[0185] The selected calcium carbonate powder is 400 mesh.

[0186] The selected stabilizer is a calcium-zinc stabilizer.

[0187] 2. The extrusion process of this substrate, its characteristics, and the selection of the backing film include the following steps:

[0188] 2.1 Add 400-mesh heavy calcium carbonate and PVC powder together to a mixer, then add stabilizer, carbon black and DOTP oil for mixing.

[0189] 2.2 The mixture from 2.1 is subjected to open milling, and the LVT substrate layer is formed by calendering;

[0190] 2.3 The wear-resistant layer, color film, and LVT substrate layer are hot-pressed together using a hot press.

[0191] 2.4 The above semi-finished products are bonded to the purchased wood-plastic composite substrate using adhesive;

[0192] 2.5 The semi-finished product from 2.4 is then glued to the LVT substrate layer again to produce cold-laid multilayer flooring. The board size is 1500*970mm. Further sawing is performed, reducing the size from 1500*970mm to 1500*225mm.

[0193] 2.6 Grooving

[0194] 2.6.1 Grooving shall be performed as required. A male groove (raised structure) shall be machined on one side of the long side (1500mm) of the board, and a female groove (recessed structure) on the other side, for splicing along the long side. A male groove (raised structure) shall be machined on one side of the short side (225mm) of the board, and a female groove (recessed structure) on the other side, for splicing along the short side. This allows adjacent boards to be tightly connected through the interlocking splicing of the male and female grooves.

[0195] 2.6.2 Grooving (planing) is performed on the upper surface edge areas of two adjacent sides of each sheet of material using a high-speed rotating tool.

[0196] For example, a piece of flooring that has been cut to the required size is divided into four sides: 1, 2, 3, and 4. Marking them clockwise, all sides 1 and 2 are planed. During the planing process, the part above the substrate layer is completely planed off, and then a small portion of the substrate layer is removed. The planing depth of the substrate layer is about 0.1-0.4mm, and the width is 2-3mm, to obtain a groove that simulates the effect of tile grout.

[0197] Experimental Example 1

[0198] By adjusting the organosilicon content in organosilicon-modified acrylic resins, modified acrylic resins with different organosilicon contents were prepared.

[0199] The preparation method is as follows:

[0200] 1) Add appropriate amounts of epoxy acrylate resin, organosilicon monomer (such as γ-glycidoxypropyltrimethoxysilane), and solvent (such as toluene, acetone, methyl ethyl ketone, etc.) to the reactor. The proportions of epoxy acrylate resin and organosilicon monomer are shown in Table 1.

[0201] Add the catalyst tetramethylammonium hydroxide.

[0202] 2) Heat the reactor to 80-100℃ and stir for 4-6 hours. Monitor the viscosity (1000-50000mPa·s(25℃)) and epoxy value of the reaction system (the epoxy value may decrease to 0.2-0.4eq / 100g after modification).

[0203] 3) Cool down to below 50℃, filter to remove impurities, and add a suitable solvent (such as toluene, acetone, methyl ethyl ketone, etc.) to adjust the viscosity (set at 1000-2000 mPa·s).

[0204] 4) Pack the finished product into a sealed container and store it in a cool, dry place.

[0205] Modified acrylic resins with varying organosilicon content were used to prepare ceramic tile-like stone-plastic flooring, following the same method as in Example 1, resulting in ceramic tile-like stone-plastic flooring with a grout-sealing effect. Furthermore, in the experimental example, the width of the grout grooves was further increased by planing for use in a water contact angle experiment.

[0206] The water contact angle refers to the contact angle formed by a water droplet on a solid surface. It is a commonly used indicator to characterize the hydrophilicity or hydrophobicity of a solid surface. Water contact angle testing can be used for the quality inspection of material surface coatings and the evaluation of the wettability of material surfaces, and is widely used in materials science, coating processes, and surface engineering.

[0207] Hydrophilicity and hydrophobicity: When the contact angle is less than 90°, it indicates that the material surface is hydrophilic, meaning that water easily spreads on the material surface. When the contact angle is greater than 90°, it indicates that the material surface is hydrophobic, meaning that water does not easily spread on its surface.

[0208] The results are shown in Table 1.

[0209] Table 1. Effect of organosilicon content on water contact angle

[0210] The comparison data in Table 1 shows that the organosilicon content reaches the highest cost-effectiveness at 30%, and increasing it to 40% has little impact on improving the water contact angle.

[0211] Test Example 2

[0212] According to the requirements of the embodiments and comparative examples, the finished product was made, the grouting area was planed out, and the stain resistance performance of the grouting area and its surroundings was compared and tested.

[0213] (1) The method for testing stain resistance is as follows:

[0214] Place the specimen in a room temperature environment.

[0215] Wipe the surface of the test specimen clean with absorbent cotton. Place a small amount of contaminant (e.g., 2-3 drops) on the upper surface of the two horizontally placed test specimens (the area to be sealed and the surrounding area). Cover the contaminant on one of the test specimens with a glass cover plate.

[0216] After 16 hours of contact, first wipe away the contaminants with a clean, soft cloth, then wash with water, followed by rinsing with water containing a wetting agent, and finally clean the surface with ethanol and dry with degreased cotton. For plates with a textured (or embossed) surface, a brush can be used to remove contaminants from the textured surface. After cleaning, place the specimen at room temperature for 24 hours, then place the specimen on the testing stage and observe the surface of the specimen from a distance of 400 mm with normal vision (or corrected to normal vision).

[0217] (2) Results representation

[0218] The effect of test materials on the surface of the specimen:

[0219] Level 5: No significant change;

[0220] Grade 4: Slight changes in gloss and / or color;

[0221] Grade 3: Moderate variation in gloss and / or color;

[0222] Grade 2: Significant changes in gloss and / or color;

[0223] Level 1: Surface deformation and / or blistering.

[0224] The results are shown in Table 2.

[0225] Table 2 Comparison of Stain Resistance of Tile Grout Strips

[0226] As shown in Table 2, the stain resistance of the ceramic tile-like stone plastic flooring with modified materials is significantly better than that of the control group in the grout groove area.

[0227] Industrial Application Examples

[0228] This application's ceramic tile-look stone-plastic flooring with a grout-sealing effect exhibits superior stain resistance compared to the comparative version. Its click-lock installation allows for wide applicability and can replace marble tiles in various scenarios, such as...

[0229] 1. Home decoration scenario

[0230] Includes living room / bedroom, kitchen / bathroom, balcony / basement.

[0231] 2. Commercial space

[0232] This includes offices / meeting rooms, shopping malls / shops, hotels / guesthouses.

[0233] 3. Public places

[0234] This includes hospitals / schools, gyms / dance studios, and so on.

[0235] The above is a further detailed description of the present invention and should not be considered as a limitation on the specific implementation of the present invention. For those skilled in the art, simple deductions or substitutions without departing from the concept of the present invention are all within the protection scope of the present invention.

Claims

1. A ceramic tile-like stone-plastic flooring, characterized in that, The imitation ceramic tile stone plastic flooring includes, from top to bottom, a wear-resistant layer, a decorative layer, a first rigid SPC substrate layer, a foamed SPC substrate layer, and a second rigid SPC substrate layer. The first rigid SPC substrate layer comprises 12-20 wt% polyvinyl chloride resin (PVC), 12-20 wt% silicone-modified acrylic resin, and 50-70 wt% calcium carbonate. The imitation ceramic tile stone plastic flooring has grooves from top to bottom, and the lowest point of the grooves does not exceed half the thickness of the first rigid SPC substrate layer; the grooves are used to simulate the grouting effect of ceramic tiles.

2. The ceramic tile-like stone-plastic flooring according to claim 1, characterized in that, The second rigid SPC substrate layer comprises 12-20 wt% polyvinyl chloride resin (PVC), 12-20 wt% silicone-modified acrylic resin, and 50-70 wt% calcium carbonate.

3. The ceramic tile-like stone-plastic flooring according to claim 1 or 2, characterized in that: The first rigid SPC substrate layer and the second rigid SPC substrate layer comprise the following raw materials in parts by weight: 20-30 parts of polyvinyl chloride resin (PVC), 80-110 parts of calcium carbonate, 2-4 parts of calcium-zinc stabilizer, 2-4 parts of acrylate copolymer (ACR), 2-4 parts of toughening agent, 0.5-3 parts of internal lubricant, 0.5-3 parts of external lubricant, 0.1-0.5 parts of carbon black, and 20-30 parts of silicone-modified acrylic resin.

4. The imitation ceramic tile stone-plastic flooring according to any one of claims 1-3, characterized in that: The raw materials for preparing the silicone-modified acrylic resin include silicone monomers and epoxy acrylic resin, wherein the silicone monomers account for 10%-50% of the total mass of the silicone monomers and epoxy acrylic resin, preferably 20%-40%, more preferably 30%-40%; and / or, the viscosity of the silicone-modified acrylic resin is 1000-2000 mPa·s.

5. The ceramic tile-like stone-plastic flooring according to claim 1, characterized in that: The texture of the decorative layer includes at least one of wood texture, marble texture, granite texture, fabric texture, carpet texture, cement texture, and metal texture; preferably marble texture.

6. The ceramic tile-like stone-plastic flooring according to claim 1, characterized in that, The foamed SPC substrate layer comprises the following raw materials in parts by weight: 40-60 parts of polyvinyl chloride resin (PVC), 70-100 parts of calcium carbonate, 30-60 parts of recycled SPC foaming material, 3-5 parts of calcium-zinc stabilizer, 1-3 parts of acrylate copolymer (ACR), 5-10 parts of foaming regulator, 0.1-0.5 parts of yellow foaming agent, 0.1-0.3 parts of white foaming agent, 0.5-3 parts of internal lubricant, and 0.5-3 parts of external lubricant.

7. The ceramic tile-like stone-plastic flooring according to claim 1, characterized in that, A UV layer is disposed above the wear-resistant layer; and / or, a sound-absorbing layer is disposed below the second rigid SPC substrate layer.

8. The imitation ceramic tile stone-plastic flooring according to any one of claims 1-3, characterized in that, The thickness of the first rigid SPC substrate layer is 0.8-1.2 mm, the thickness of the foamed SPC substrate layer is 3.2-12.0 mm, and the thickness of the second rigid SPC substrate layer is 0.8-1.2 mm; and / or, the first rigid SPC substrate layer, the foamed SPC substrate layer, and the second rigid SPC substrate layer are prepared by a co-extrusion process.

9. The imitation ceramic tile stone-plastic flooring according to any one of claims 1-4, characterized in that, The grooves are created by planing.

10. A method for preparing ceramic tile-like stone-plastic flooring, characterized in that, Includes the following steps: S1. Heat and mix the raw materials for the rigid SPC substrate layer; heat and mix the raw materials for the foamed SPC substrate layer; S2. Transfer the raw materials for the rigid SPC substrate layer and the foamed SPC substrate layer to the extruder; S3. Inject the foamed SPC substrate material into the mold through the central flow channel of the merging core; inject the rigid SPC substrate material into the mold through the side flow channel of the merging core, and co-extrude it through the distributor to form a rough plate with the upper layer being the first rigid SPC substrate layer, the middle layer being the foamed SPC substrate layer, and the lower layer being the second rigid SPC substrate layer. S4. A decorative layer is provided on the first hard SPC substrate layer of the rough plate, and a wear-resistant layer is provided on the decorative layer. S5. Apply a UV-curable transparent varnish to the wear-resistant layer to form a UV layer; S6. The pattern is printed on the upper surface of the board by the printing roller; S7. Planing to form a groove with a sealing effect, the planed part includes a UV layer, a wear-resistant layer, a decorative layer and part of the first hard SPC substrate layer, and the lowest point of the planing does not exceed half the thickness of the first hard SPC substrate layer.

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