Outdoor laminate floor and a manufacturing technique thereof

Abstract

An outdoor laminate floor includes a substrate made from PVC foaming and a wear-resistant, anti-aging covering film that is adhered to the surface of the substrate. The covering film overlays the surface of the substrate after being adhered by hot glue. The covering film is a modified weather-resistant polymeric film. In this way, the outdoor laminate floor has a simple and compact structure, and solid wood is replaced with the substrate and the covering film, which not only protects environment by reducing the use of solid wood, but also reduces the manufacturing cost and improves the competitive edge on the market, owing to the low-cost substrate and covering film.

Claims

1. An outdoor laminate floor, comprising: a substrate, wherein the substrate is made from PVC foaming, and a covering film, wherein the covering film is wear-resistant and anti-aging, and is adhered to a surface of the substrate, the covering film overlays the surface of the substrate after being adhered by hot glue; and the covering film is a modified weather-resistant polymeric film; wherein the substrate is rectangular, a protrusion extends from a first end of the substrate, the protrusion is configured to be engaged with a groove, wherein the groove is arranged at a second end of the substrate; and the covering film comprises a full-covering film and a half-covering film, wherein the full-covering film overlays the substrate, and the half-covering film overlays two end surfaces of the substrate; wherein texture patterns are arranged on the substrate, the texture patterns are arranged between an end surface of the two end surfaces of the substrate and a first end surface of the covering film, wherein the first end surface of the covering film is away from the substrate, and the texture patterns comprise wood-texture patterns; wherein a second end surface of the covering film is coated with a first affinity reagent and printed with the texture patterns, an end surface of the texture patterns is coated with a second affinity reagent and then coated with the hot glue, wherein the end surface of the texture patterns is away from the covering film; an end of the hot glue is coated with a third affinity reagent and securely affixed onto the substrate, wherein the end of the hot glue is away from the covering film.

2. The outdoor laminate floor of claim 1, wherein the texture patterns are arranged on a sticker, both end surfaces of the sticker are adhered between the substrate and the covering film by the hot glue.

3. The outdoor laminate floor of claim 1, wherein the texture patterns are printed inside the covering film.

4. A process for manufacturing the outdoor laminate floor of claim 1, comprising the following steps: preparing a board in a standard format by using the PVC foaming to form the substrate; arranging the texture patterns; and applying the covering film.

5. The process according to claim 4, wherein the texture patterns are arranged on a sticker, both end surfaces of the sticker are adhered between the substrate and the covering film by the hot glue.

6. The process according to claim 4, wherein the texture patterns are printed inside the covering film.

7. An outdoor laminate floor, comprising: a substrate, wherein the substrate is made from PVC foaming, and a covering film, wherein the covering film is wear-resistant and anti-aging, and is adhered to a surface of the substrate, the covering film overlays the surface of the substrate after being adhered by hot glue; and the covering film is a modified weather-resistant polymeric film; wherein the substrate is rectangular, a protrusion extends from a first end of the substrate, the protrusion is configured to be engaged with a groove, wherein the groove is arranged at a second end of the substrate; and the covering film comprises a full-covering film and a half-covering film, wherein the full-covering film overlays the substrate, and the half-covering film overlays two end surfaces of the substrate; wherein texture patterns are arranged on the substrate, the texture patterns are arranged between an end surface of the two end surfaces of the substrate and a first end surface of the covering film, wherein the first end surface of the covering film is away from the substrate, and the texture patterns comprise wood-texture patterns; wherein a second end surface of the covering film is coated with a first affinity reagent and then coated with the hot glue, an end surface of the hot glue is coated with a second affinity reagent and printed with the texture patterns, wherein the end surface of the hot glue is away from the covering film; an end surface of the texture patterns is securely affixed onto the substrate by the hot glue, wherein the end surface of the texture patterns is away from the covering film.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is the schematic structure of the present invention;

(2) FIG. 2 is the schematic structure of the present invention;

(3) In the figures: 1—substrate; 2—texture pattern; 3—covering film; 4—protrusion; 5—groove.

DETAILED DESCRIPTION

(4) In order to make clear the technical approaches implemented in this invention, features of this invention, purposes and effectiveness, the present invention is further elucidated with reference to specific embodiments.

Embodiment 1

(5) As FIG. 1 shows, an outdoor laminate floor comprising a substrate 1 made from PVC foaming and wear-resistant, anti-aging covering film 3 that is adhered to the surface of the substrate 1 by hot glue. Specifically, the covering film 3 is modified weather-resistant polymeric film and the substrate 1 is overall rectangular, extended with a protrusion 4 at one end, the protrusion 4 being used for snap-on with the groove 5 engineered at the other end.

(6) In order for the outdoor laminate floor provided in this invention to apply to various outdoor spots, texture patterns 2 are set on the substrate 1, the texture patterns 2 being set in between the end surface of the substrate 1 and the distant end surface of the covering film 3 to the substrate 1. Specifically, the texture pattern 2 is wood-texture pattern, the wood-texture pattern being set on a sticker, both end surfaces of the sticker being individually adhered to between the substrate 1 and the covering film 3 by hot glue.

(7) In this invention, the technique for manufacturing the outdoor laminate floor comprises the following steps:

(8) S1: prepare standard format of board via PVC foaming, thereby forming substrate;

(9) S2: prepare a sticker which is clipped into a shape that matches the substrate and print the desired pattern onto the sticker by a 3D printer for later use;

(10) S3: coat both sides of the sticker resulted in S2 with hot glue and adhere the sticker onto the substrate;

(11) S4: adhere modified weather-resistant polymeric film onto the distant end surface of the sticker to the substrate, thereby forming the said outdoor laminate floor.

Embodiment 2

(12) As FIG. 1 shows, the content of this embodiment is basically identical to that of Embodiment 1. With common part left out, the difference lies in: in order for the outdoor laminate floor provided in this invention to apply to various outdoor spots, texture patterns 2 are set on the substrate 1, the texture patterns 2 being set in between the end surface of the substrate 1 and the distant end surface of the covering film 3 to the substrate 1. Specifically, one end surface of the covering film 3 is coated with affinity reagent and printed with texture patterns 2, the distant end surface of the texture patterns 2 to the covering film 3 being coated with affinity reagent and then with hot glue, the distant end of the hot glue to the covering film 3 being coated with affinity reagent and securely affixed onto the substrate 1.

(13) In this invention, the technique for manufacturing the outdoor laminate floor comprises the following steps:

(14) S1: prepare standard format of board via PVC foaming, thereby forming substrate;

(15) S2: one end surface of the covering film is coated with affinity reagent and printed with texture patterns, the distant end surface of the texture patterns to the covering film being coated with affinity reagent and then with hot glue;

(16) S3: the distant end of the hot glue to the covering film is coated with affinity reagent and securely affixed onto the substrate, thereby forming the said outdoor laminate floor.

Embodiment 3

(17) As FIG. 1 shows, the content of this embodiment is basically identical to that of Embodiment 1. With common part left out, the difference lies in: in order for the outdoor laminate floor provided in this invention to apply to various outdoor spots, texture patterns 2 are set on the substrate 1, the texture patterns 2 being set in between the end surface of the substrate 1 and the distant end surface of the covering film 3 to the substrate 1. Specifically, one end surface of the covering film 3 is coated with affinity reagent and then with hot glue, the distant end surface of the hot glue to the covering film 3 being coated with affinity reagent and printed with texture patterns 2, the distant end surface of the texture patterns 2 to the covering film 3 being securely affixed onto the substrate 1 by hot glue.

(18) In this invention, the technique for manufacturing the outdoor laminate floor comprises the following steps:

(19) S1: prepare standard format of board via PVC foaming, thereby forming substrate;

(20) S2: one end surface of the covering film is coated with affinity reagent and then with hot glue, the distant end surface of the hot glue to the covering film being coated with affinity reagent and printed with texture patterns;

(21) S3: the distant end surface of the texture patterns to the covering film is securely affixed onto the substrate by hot glue.

Embodiment 4

(22) As FIG. 2 shows, the content of this embodiment is basically identical to that of Embodiment 1. With common part left out, the difference lies in: in order for the outdoor laminate floor provided in this invention to apply to various outdoor spots, texture pattern 2 is set on the substrate 1, the texture pattern 2 being set in between the end surface of the substrate 1 and the distant end surface of the covering film 3 to the substrate 1. Specifically, the texture pattern 2 is wood-texture pattern, the wood-texture pattern being printed inside the covering film 3.

(23) In this invention, the technique for manufacturing the outdoor laminate floor comprises the following steps:

(24) S1: prepare standard format of board via PVC foaming, thereby forming substrate;

(25) S2: coat the substrate with hot glue and then overlay the substrate with modified weather-resistant polymeric film, during which thickness of the modified weather-resistant polymeric film is half as finally required of the product;

(26) S3: coat the modified weather-resistant polymeric film with hot glue and adhere the associated wood-texture pattern onto the surface of the modified weather-resistant polymeric film;

(27) S4: coat the wood-texture pattern with hot glue and overlay the wood-texture pattern with modified weather-resistant polymeric film, thereby forming the said outdoor laminate floor.

(28) Thickness of the modified weather-resistant polymeric film overlay in S4 is half as finally required of modified weather-resistant polymeric film.

(29) Control 1:

(30) PVC covering film from U.S. is selected and made into outdoor floors identical to the above embodiments in structure and specification.

(31) Control 2:

(32) Commercially available regular outdoor floors are selected. Specifically, outdoor solid wood floors made of preservative-treated Scots pine provided by Shanghai Jiayan Industries Co., Ltd. are selected.

(33) Test the outdoor laminate floors resulted in Embodiments 1˜4 for UV resistance and antistatic performance that are measured in terms of UV (particularly at wavelengths 290-400 nm) transmittance and specific resistance Rs (resistance between corresponding edges per square unit of test samples) respectively. Meanwhile, other performance tests are conducted and compared to Control 1 and Control 2. The testing results are shown in Table 1:

(34) TABLE-US-00001 TABLE 1 Technical Embodi- Embodi- Embodi- Embodi- Control Control Item specifications ment 1 ment 2 ment 3 ment 4 1 2 Scratch ≥17, surface 45 46 45 45 30 20 resistance ornament not (N) broken Surface ≥55 92 93 93 93 85 60 hardness (HD) Surface Wear-resistant 16500 16660 16950 16950 17060 12000 wear- turns r ≥ 4000 resistance for film layer ≤0.13 g/100r, 0.022 0.022 0.022 0.022 0.025 0.027 paint film not worn away Skid ≤35 15 15 15 15 18 30 resistance Boiled in Pass Pass Pass Pass Pass Fail high and low tempera- ture water Elastic 24.2 24.3 24.3 24.3 20 18 Modulus (GPa) Surface 9.6 × 10.sup.8 9.6 × 10.sup.8 9.6 × 10.sup.8 9.6 × 10.sup.8 8 × 10.sup.8 6 × 10.sup.8 Resistance (MΩ) Thermal 475 474 476 476 450 420 shock (S) 288° C.

(35) The mechanism, main features and characteristics of this invention are shown and described above. Technical personnel in this industry should understand that the present invention is not limited to the above embodiments that together with the above descriptions only demonstrate the mechanism of the present invention. Within the idea and scope of this invention, it will derive various adaptions and improvements that will all fall into the protected range of this invention. The range to be protected for this invention is defined by the enclosed claims and equivalents thereof.