STONE PLASTIC COMPOSITE (SPC) FLOOR COMPRISING DECORATIVE SURFACE

Abstract

A stone plastic composite (SPC) floor includes a decorative surface. The SPC floor has an SPC substrate and a decorative surface formed on the SPC substrate; the decorative surface is a wooden board or a bamboo board; the moisture content of the decorative surface is controlled within 5-7%. The SPC substrate is divided into an upper layer, a middle layer, and a lower layer, and the main components of the SPC substrate comprise polyvinyl chloride resin powder, calcium carbonate, a calcium-zinc stabilizer, an inner lubricant, PE wax, chlorinated polyethylene (CPE), acrylic ester (ACR), a composite lubricant, and a coloring agent. The SPC floor can ensure that the decorative surface does not wrap and deform, and other performances of the floor are not affected, and thus is low in costs.

Claims

1.-10. (canceled)

11. A stone plastic composite (SPC) floor comprising a decorative surface, wherein the SPC floor comprises an SPC substrate and a decorative surface formed on the SPC substrate, the decorative surface is a wooden board or a bamboo board, and the moisture content of the decorative surface is controlled within 5-7%.

12. The stone plastic composite (SPC) floor comprising a decorative surface of claim 11, wherein the main components of the SPC substrate comprise polyvinyl chloride resin powder, calcium carbonate, a calcium-zinc stabilizer, an inner lubricant, PE wax, chlorinated polyethylene (CPE), acrylic ester (ACR), a composite lubricant, and a coloring agent.

13. The stone plastic composite (SPC) floor comprising a decorative surface of claim 12, wherein the SPC substrate is divided into an upper layer, a middle layer, and a lower layer, wherein the components of the upper layer comprise 100 parts of polyvinyl chloride resin powder, 270-300 parts of calcium carbonate, 4-6 parts of calcium-zinc stabilizer, 0.5-1 part of inner lubricant, 0.6-1.0 part of PE wax, 2-5 parts of chlorinated polyethylene (CPE), 1-3 parts of acrylic ester (ACR), 0.5-1 part of composite lubricant, and 0.5-0.7 parts of coloring agent; wherein the components of the middle layer comprise 100 parts of polyvinyl chloride resin powder, 350-380 parts of calcium carbonate, 4-6 parts of calcium-zinc stabilizer, 0.5-0.8 parts of inner lubricant, 0.6-0.9 parts of PE wax, 2-4 parts of chlorinated polyethylene (CPE), 1-3 parts of acrylic ester (ACR), 0.5-0.8 parts of composite lubricant, and 0.5-0.7 parts of coloring agent; wherein the components of the lower layer comprise 100 parts of polyvinyl chloride resin powder, 270-300 parts of calcium carbonate, 4-6 parts of calcium-zinc stabilizer, 0.5-1 part of inner lubricant, 0.6-1.0 part of PE wax, 2-5 parts of chlorinated polyethylene (CPE), 1-3 parts of acrylic ester (ACR), 0.5-1 part of composite lubricant, and 0.5-0.7 parts of coloring agent.

14. The stone plastic composite (SPC) floor comprising a decorative surface of claim 12, wherein the middle layer has a thickness of 1.5 mm-4 mm.

15. The stone plastic composite (SPC) floor comprising a decorative surface of claim 14, wherein the substrate has a total thickness of 4-7 mm.

16. The stone plastic composite (SPC) floor comprising a decorative surface of claim 11, wherein the decorative surface has a thickness of 0.5-1.5 mm.

17. The stone plastic composite (SPC) floor comprising a decorative surface of claim 13, wherein the SPC substrate board is formed by co-extrusion.

18. The stone plastic composite (SPC) floor comprising a decorative surface of claim 11, wherein an adhesive layer is arranged between the decorative surface and the SPC substrate.

19. The stone plastic composite (SPC) floor comprising a decorative surface of claim 18, wherein the adhesive layer is formed by a roller coating and cold pressing process.

20. A process for preparing the stone plastic composite (SPC) floor comprising a decorative surface of claim 11, comprising the steps: S-1. Preparing a SPC substrate board, and sanding the board to fix its thickness, thus obtaining a SPC substrate; S-2. Laminating the decorative surface and the SPC substrate with cold glue, and performing cold pressing; S-3. Performing surface sanding and wire drawing after the cold pressing; and S-4. Subjecting the surface to UV treatment to obtain a finished product.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

Description of the Drawings

[0031] FIG. 1 is a schematic structural diagram of a floor obtained in one embodiment of the present invention;

[0032] FIG. 2 is a simplified schematic flow chart of preparing an SPC substrate board in one embodiment of the present invention.

PREFERRED EMBODIMENTS OF THE INVENTION

Preferred Modes of Implementing the Invention

Embodiment 1

[0033] A stone plastic composite (SPC) floor comprising a decorative surface, the floor comprises an SPC substrate 10, a decorative surface 20, and an adhesive layer 30 bonding the SPC substrate and the decorative surface, the decorative surface 20 being a wood board or a bamboo board, the moisture content of the decorative surface being controlled within 5-7%. The adhesive layer 30 was formed with a cold glue polyurethane adhesive by roller coating and cold pressing.

[0034] The SPC substrate was divided into an upper layer, a middle layer, and a lower layer, the main components of the upper layer and the lower layer comprising PVC resin powder and calcium carbonate, and the preferred compositions are listed in Table 1:

TABLE-US-00001 TABLE 1 Compositions of the upper and lower layers Input amount Input amount Input amount Comparative Material in embodiment 1 in embodiment 2 in embodiment 3 example 4 PVC resin powder 100 kg 100 kg 100 kg 100 kg Calcium carbonate 303 kg 285 kg 270 kg 150 kg Calcium-zinc stabilizer 5 kg 5 kg 5 kg 5 kg Composite lubricant 0.8 kg 0.8 kg 0.7 kg 0.8 kg (LUBDE A380) PE wax 1 kg 0.6 kg 0.7 kg 1 kg Stearic acid SP60 0.8 kg 0.5 kg 0.8 kg 0.8 kg CPE 5 kg 4 kg 3 kg 15 kg ACR 2 kg 2.5 kg 1.5 kg 2 kg Carbon black 0.5 kg 0.5 kg 0.5 kg 0.5 kg (coloring agent)

[0035] The main components of the middle layer comprised PVC resin powder and calcium carbonate, with the preferred compositions listed in Table 2:

TABLE-US-00002 TABLE 2 Compositions of the middle layer Input amount Input amount Input amount Comparative Material in embodiment 1 in embodiment 2 in embodiment 3 example 4 PVC resin powder 100 kg 100 kg 100 kg 100 kg Calcium carbonate 380 kg 365 kg 350 kg 270 kg Calcium-zinc stabilizer 5 kg 4 kg 5 kg 15 kg Composite lubricant 0.8 kg 0.7 kg 0.6 kg 0.8 kg (LUBDE A380) PE wax 0.9 kg 0.8 kg 0.7 kg 0.9 kg Stearic acid SP60 0.6 kg 0.7 kg 0.7 kg 0.6 kg CPE 4 kg 3 kg 3.5 kg 4 kg ACR 2 kg 2 kg 15 kg 2 kg

[0036] The SPC substrate had the components listed in Tables 1-2.

[0037] In the present embodiment, as shown in FIG. 2, the method for manufacturing the floor comprised first feeding raw materials into extruder A according to the materials and input amounts listed in Table 1; and then feeding raw materials into extruder B according to Table 2. Extruder A extruded the upper and lower layers of equal mass and equal thickness at the same time, and extruder B extruded the middle layer. Then, the extrudate entered the runner distributor of the die, so that the middle layer was located between the upper layer and the lower layer, and then it entered the die orifice for extrusion into an SPC substrate. The middle layer had a thickness of 4 mm. The upper and lower layers had the same thickness of 1.0 mm.

[0038] Each extruder had a main engine barrel temperature of 200-210° C., a confluence core temperature of 160-180° C., a die temperature of 200-210° C., a main engine speed of 18-20 r/min, a feeding speed of 7-16 r/min, an extrusion speed of 1400-1450 mm/min, and a roller temperature of 175-180° C.

[0039] Thus, there was no adhesive between the upper, middle and lower layers. The board ejected from the die was pressed between a shading roller 1 and a mirror roller 2 to form shade, and the substrate was conveyed to extrusion between a mirror roller 3 and an embossing roller 4 to eject a board, which was shaped, cooled, cut, and shaped to obtain a stone plastic composite (SPC) substrate. Thus, there was no adhesive between the three layers, which is more environmentally friendly and reduces the cost of floor production.

[0040] The method for manufacturing the bamboo veneer (wooden veneer) was as follows: the bottom surface of the bamboo veneer (wooden veneer) was sanded with a 120-150 mesh sand belt until the surface became smooth and was moved into a kiln, the kiln entrance was closed for stepped heating, the heating continued after the temperature had been kept at 35° C. for 10 hours, the temperature needed to reach 50° C. within 24 hours, when the temperature had reached 50° C., spraying was performed for 3 hours, so that the humidity had a difference of 3 percent with the temperature, then, an equilibrium was maintained for 24 hours at 50° C., so that the humidity fell to have a difference of 10 percent with the temperature, then, spraying was performed for 3 hours at 50° C., so that the humidity had a difference of 5 percent with the temperature, an equilibrium was maintained for 60 hours at 50° C., so that the humidity fell to have a difference of 10 percent with the temperature, until a spot check showed that the oven-dry moisture content had reached the moisture content required for a slab, with the moisture content controlled within 5-7%. The decorative surface had a thickness of 0.5 mm-1.5 mm.

[0041] The SPC substrate and the decorative layer needed to be compounded by glue. In this embodiment, the glue is preferably cold glue polyurethanes, and Polyurethane Reactive (PUR) may also be used. The cold glue compounding process parameters of the process for laminating the SPC substrate and the decorative layer are listed in Table 3.

TABLE-US-00003 TABLE 3 Cold glue compounding process parameters of the process for laminating the SPC substrate and decorative layer Glue Glue Roller coating Key point Ratio of curing temperature/ amount/ temperature/ in process agent to glue ° C. (g/m.sup.2) ° C. Process 1:5 20-30 138-170 20-30 requirement

[0042] A polyisocyanate curing agent was used as the curing agent.

[0043] The process parameters for cold pressing the SPC substrate and the decorative layer are listed in Table 4.

TABLE-US-00004 TABLE 4 Process parameters for cold pressing the SPC substrate and the decorative layer Key point Cold in process Unit pressure Temperature/° C. pressing time Process 1.5 MPa/cm.sup.2 25-30 6 h requirement

SPECIFIC EMBODIMENTS

Embodiments of the Invention

Embodiment 2

[0044] This embodiment differed from embodiment 1 in the compositions of the upper layer, the middle layer, and the lower layer, details of which are listed in Tables 1-2. Each extruder had a main engine barrel temperature of 170-180° C., a confluence core temperature of 140-150° C., a die temperature of 170-210° C., a main engine speed of 18-20 r/min, a feeding speed of 7-16 r/min, an extrusion speed of 1400-1500 mm/min, and a roller temperature of 175-200° C. The middle layer had a thickness of 3 mm. The upper and lower layers had the same thickness of 1.5 mm.

Embodiment 3

[0045] This embodiment differed from embodiment 1 in the compositions of the upper layer, the middle layer, and the lower layer, details of which are listed in Tables 1-2. Each extruder had a main engine barrel temperature of 180-190° C., a confluence core temperature of 140-180° C., a die temperature of 180-190° C., a main engine speed of 18-20 r/min, a feeding speed of 7-16 r/min, an extrusion speed of 1500 mm/min, and a roller temperature of 180-185° C.