Stone-plastic hot pressing flooring and manufacturing method thereof

Abstract

The present invention provides stone-plastic hot pressing flooring including a stone-plastic base material part which includes a middle material layer, a stone-plastic substrate layer, and a bottom material layer sequentially arranged side by side; —a color film layer, located at one side of an upper surface of the stone-plastic base material part; —a first wear-resistant layer, located at one side of an upper surface of the color film layer; and —a second wear-resistant layer, located at one side of a lower surface of the stone-plastic base material part; and wherein the middle material layer and the bottom material layer are mainly composed of polyvinyl chloride, plasticizer, stabilizer, carbon black, and stone powder.

Claims

1. A manufacturing method of stone-plastic hot pressing flooring, wherein the stone-plastic hot pressing flooring comprises a stone-plastic base material part, comprising a middle material layer, a stone-plastic substrate layer, and a bottom material layer sequentially arranged side by side; a color film layer, located at one side of an upper surface of the stone-plastic base material part; a first wear-resistant layer, located at one side of an upper surface of the color film layer; and a second wear-resistant layer, located at one side of a lower surface of the stone-plastic base material part; wherein both the middle material layer and the bottom material layer are mainly composed of polyvinyl chloride, plasticizer, stabilizer, carbon black, and stone powder, the manufacturing method comprising the following steps: adding and mixing raw materials of the bottom material layer to obtain a bottom material layer intermediate, and then internal-mixing and calendering the bottom material layer intermediate to obtain a bottom material layer sheet; adding and mixing raw materials of the middle material layer to obtain a middle material layer intermediate, and then internal-mixing and calendering the middle material layer intermediate to obtain a middle material layer sheet; mixing, internal-mixing, and calendering raw materials of the stone-plastic substrate layer to obtain a stone-plastic substrate layer sheet; sequentially arranging a first wear-resistant layer film, a color film, the middle material layer sheet, the stone-plastic substrate layer sheet, the bottom material layer sheet, and a second wear-resistant layer film, and then carrying out a hot pressing process to obtain a finished product; and a cold pressing process, wherein the cold pressing process is carried out after the hot pressing process and comprises a first cold pressing process and a second cold pressing process.

2. The manufacturing method of the stone-plastic hot pressing flooring according to claim 1, wherein in the hot pressing process, a pressure is controlled in a range of 3-6 MPa, a temperature is controlled in a range of 125-145° C., and hot pressing time is controlled in a range of 1500-2100 s.

3. The manufacturing method of the stone-plastic hot pressing flooring according to claim 1, wherein in the first cold pressing process, a pressure is controlled in a range of 5-8 MPa, a temperature is controlled in a range of 80-145° C., and cold pressing time is controlled in a range of 600-800 s.

4. The manufacturing method of the stone-plastic hot pressing flooring according to claim 1, wherein in the second cold pressing process, a pressure is controlled in a range of 8-15 MPa, a temperature is controlled in a range of 23-80° C., and cold pressing time is controlled in a range of 800-1000 s.

5. The manufacturing method of the stone-plastic hot pressing flooring according to claim 1, wherein after calendering the bottom material layer intermediate or the middle material layer intermediate or the stone-plastic substrate layer, further comprising a slicing operation.

Description

DETAILED DESCRIPTION OF THE INVENTION

(1) A specific implementation of the present invention is further described in detail below in combination with embodiments. The following embodiments are used to illustrate the present invention, but are not intended to limit the scope of the present invention.

(2) All the “a” in the present invention should be interpreted as “at least one” or “one or two or more”.

(3) The present invention provides stone-plastic hot pressing flooring including a stone-plastic base material part which includes a middle material layer, a stone-plastic substrate layer, and a bottom material layer sequentially arranged side by side; a color film layer, located at one side of an upper surface of the stone-plastic base material part; a first wear-resistant layer, located at one side of an upper surface of the color film layer; and a second wear-resistant layer, located at one side of a lower surface of the stone-plastic base material part; and wherein the middle material layer and the bottom material layer are mainly composed of polyvinyl chloride, plasticizer, stabilizer, carbon black, and stone powder.

(4) Both thicknesses of the first wear-resistant layer and the second wear-resistant layer are in a range of 0.07-0.7 mm, and a thickness of the color film layer is in a range of 0.07-0.7 mm; and a thickness of the stone-plastic substrate layer is in a range of 1.5-4.0 mm, a thickness of the middle material layer is in a range of 1.8-2.0 mm, and a thickness of the bottom material layer is in a range of 1.6-1.8 mm.

(5) Densities of the first wear-resistant layer and the second wear-resistant layer are in a range of 1.10-1.40 g/cm.sup.3.

(6) A density of the stone-plastic substrate layer is in a range of 1.8-2.1 g/cm.sup.3, a density of the middle material layer is in a range of 1.6-2.0 g/cm.sup.3, and a density of the bottom material layer is in a range of 1.6-2.0 g/cm.sup.3.

(7) Parts by weight of polyvinyl chloride, plasticizer, stabilizer, carbon black, and stone powder in the middle material layer are 100:(35-40):(2-5):(0.5-2):(400-500).

(8) Parts by weight of polyvinyl chloride, plasticizer, stabilizer, carbon black, and stone powder in the bottom material layer are 100:(25-35):(2-5):(0.5-2):(100-200).

(9) The plasticizer is made from dioctyl terephthalate.

(10) A contraction rate of the stone-plastic hot pressing flooring is in a range of 0.60%-0.90%.

(11) An expansion rate of the stone-plastic hot pressing flooring is in a range of 0.10%-0.15%.

(12) A mute value of the stone-plastic hot pressing flooring is in a range of 65-75 decibels.

(13) The present invention further provides a manufacturing method of the above-mentioned stone-plastic hot pressing flooring including the following steps:

(14) adding and mixing raw materials of the bottom material layer according to the above mentioned formula ratio to obtain a bottom material layer intermediate, and then internal-mixing and calendering the bottom material layer intermediate to obtain a bottom material layer sheet;

(15) adding and mixing raw materials of a middle material layer according to the above mentioned formula ratio to obtain a middle material layer intermediate, and then internal-mixing and calendering the middle material layer intermediate to obtain a middle material layer sheet;

(16) mixing, internal-mixing, and calendering raw materials of the stone-plastic substrate layer to obtain a stone-plastic base matter sheet; and

(17) sequentially arranging a first wear-resistant layer film, a color film, the middle material layer sheet, the stone-plastic base matter sheet, the bottom material layer sheet, and a second wear-resistant layer film, and then carrying out a hot pressing process to obtain a finished product.

(18) In the hot pressing process, a pressure is controlled in a range of 3-6 MPa, a temperature is controlled in a range of 125-145° C., and hot pressing time is controlled in a range of 1500-2100 s.

(19) The manufacturing method of the stone-plastic hot pressing flooring further includes a cold pressing process. The cold pressing process is carried out after the hot pressing process and includes a first cold pressing process and a second cold pressing process.

(20) In the first cold pressing process, a pressure is controlled in a range of 5-8 MPa, a temperature is controlled in a range of 80-145° C., and cold pressing time is controlled in a range of 600-800 s.

(21) In the second cold pressing process, a pressure is controlled in a range of 8-15 MPa, a temperature is controlled in a range of 23-80° C., and cold pressing time is controlled in a range of 800-1000 s.

(22) After calendering the bottom material layer intermediate or the middle material layer intermediate or the stone-plastic substrate layer, a slicing operation is further included.

(23) The formula of the stone-plastic substrate layer of the present embodiment is:

(24) TABLE-US-00001 Name Amount (kg) PVC-SG5 50 stone powder at 400 mesh 110 stabilizer 6 stearic acid 0.7 PE wax 0.6 ACR 4 CPE (chlorinated polyethylene) 4

(25) ACR is a series of impact modifiers.

(26) A specific description is carried out by embodiments below.

Embodiment One

(27) A stone-plastic hot pressing flooring includes a stone-plastic base material part, and the stone-plastic base material part includes a middle material layer, a stone-plastic substrate layer, and a bottom material layer sequentially arranged side by side; a color film layer, located at one side of an upper surface of the stone-plastic base material part; a first wear-resistant layer, located at one side of an upper surface of the color film layer; and a second wear-resistant layer, located at one side of a lower surface of the stone-plastic base material part; and wherein the middle material layer and the bottom material layer are mainly composed of polyvinyl chloride, dioctyl terephthalate, plasticizer, stabilizer, carbon black, and stone powder.

(28) Thicknesses of the first wear-resistant layer and the second wear-resistant layer are 0.07 mm, and a thickness of the color film layer is 0.07 mm; and a thickness of the stone-plastic substrate layer is 1.5 mm, a thickness of the middle material layer is 1.8 mm, and a thickness of the bottom material layer is 1.6 mm.

(29) Densities of the first wear-resistant layer and the second wear-resistant layer are 1.10 g/cm.sup.3. A density of the stone-plastic substrate layer is 1.8 g/cm.sup.3, a density of the middle material layer is 1.6 g/cm.sup.3, and a density of the bottom material layer is 1.6 g/cm.sup.3.

(30) Parts by weight of polyvinyl chloride, plasticizer, stabilizer, carbon black, and stone powder in the middle material layer are 100:35:2-5:0.5:400. Parts by weight of polyvinyl chloride, plasticizer, stabilizer, carbon black, and stone powder in the bottom material layer are 100:25:2:0.5:100.

(31) The manufacturing process thereof includes the following steps: 1) adding raw materials of a bottom material layer according to the above-mentioned formula ratio and mixing the raw materials to obtain a bottom material layer intermediate, and then internal-mixing and calendering the bottom material layer intermediate to obtain a bottom material layer sheet; 2) adding raw materials of a middle material layer according to the above-mentioned formula ratio and mixing the raw materials to obtain a middle material layer intermediate, and then internal-mixing and calendering the middle material layer intermediate to obtain a middle material layer sheet; 3) mixing, internal-mixing, calendering, and slicing raw materials of the stone-plastic substrate layer to obtain a stone-plastic substrate layer sheet; and 4) sequentially arranging a first wear-resistant layer film, a color film, the middle material layer sheet, the stone-plastic substrate layer sheet, the bottom material layer sheet, and a second wear-resistant layer film, and then carrying out a hot pressing process to obtain a finished product.

(32) In the hot pressing process, a pressure is controlled at 3 MPa, a temperature is controlled at 125° C., and hot pressing time is controlled at 1500 s.

(33) The cold pressing process includes a first cold pressing process and a second cold pressing process. In the first cold pressing process, a pressure is controlled at 5 MPa, a temperature is controlled at 80° C., and cold pressing time is controlled at 600 s. In the second cold pressing process, a pressure is controlled at 8 MPa, a temperature is controlled at 23° C., and cold pressing time is controlled at 800 s.

(34) The performance of the obtained product is as follows:

(35) TABLE-US-00002 Project name Stone-plastic hot pressing hardness 65HD expansion rate at 50° C. 0.10% contraction rate at 80° C. 0.60% warpage at 80° C. 0.4 mm mute value 65 decibels

Embodiment Two

(36) A stone-plastic hot pressing floor includes a stone-plastic base material part, and the stone-plastic base material part includes a middle material layer, a stone-plastic substrate layer, and a bottom material layer sequentially arranged side by side; a color film layer, located at one side of an upper surface of the stone-plastic base material part; a first wear-resistant layer, located at one side of an upper surface of the color film layer; and a second wear-resistant layer, located at one side of a lower surface of the stone-plastic base material part; and wherein the middle material layer and the bottom material layer are mainly composed of polyvinyl chloride, dioctyl terephthalate, plasticizer, stabilizer, carbon black, and stone powder.

(37) Thicknesses of the first wear-resistant layer and the second wear-resistant layer are 0.7 mm, and a thickness of the color film layer is 0.7 mm; and a thickness of the stone-plastic substrate layer is 4.0 mm, a thickness of the middle material layer is 2.0 mm, and a thickness of the bottom material layer is 1.8 mm.

(38) Densities of the first wear-resistant layer and the second wear-resistant layer are 1.40 g/cm.sup.3. A density of the stone-plastic substrate layer is 2.1 g/cm.sup.3, a density of the middle material layer is 2.0 g/cm.sup.3, and a density of the bottom material layer is 2.0 g/cm.sup.3.

(39) Parts by weight of polyvinyl chloride, plasticizer, stabilizer, carbon black, and stone powder in the middle material layer are 100:40:5:2:500.

(40) Parts by weight of polyvinyl chloride, plasticizer, stabilizer, carbon black, and stone powder in the bottom material layer are 100:35:5:2:200.

(41) The manufacturing process thereof includes the following steps: 1) adding raw materials of a bottom material layer according to the above-mentioned formula ratio and mixing the raw materials to obtain a bottom material layer intermediate, and then internal-mixing and calendering the bottom material layer intermediate to obtain a bottom material layer sheet; 2) adding raw materials of a middle material layer according to the above-mentioned formula ratio and mixing the raw materials to obtain a middle material layer intermediate, and then internal-mixing and calendering the middle material layer intermediate to obtain a middle material layer sheet; 3) mixing, internal-mixing, calendering, and slicing raw materials of the stone-plastic substrate layer to obtain a stone-plastic substrate layer sheet; and 4) sequentially arranging a first wear-resistant layer film, a color film, the middle material layer sheet, the stone-plastic substrate layer sheet, the bottom material layer sheet, and a second wear-resistant layer film, and then carrying out a hot pressing process to obtain a finished product.

(42) In the hot pressing process, a pressure is controlled at 6 MPa, a temperature is controlled at 145° C., and hot pressing time is controlled at 2100 s.

(43) The cold pressing process includes a first cold pressing process and a second cold pressing process. In the first cold pressing process, a pressure is controlled at 8 MPa, a temperature is controlled at 145° C., and cold pressing time is controlled at 800 s. In the second cold pressing process, a pressure is controlled at 15 MPa, a temperature is controlled at 80° C., and cold pressing time is controlled at 1000 s.

(44) The performance of the obtained product is as follows:

(45) TABLE-US-00003 Project name Stone-plastic hot pressing hardness 62 HD expansion rate at 50° C. 0.15% contraction rate at 80° C.  0.9% warpage at 80° C. 0.3 mm mute value 75 decibels

Embodiment Three

(46) A stone-plastic hot pressing floor includes a stone-plastic base material part, and the stone-plastic base material part includes a middle material layer, a stone-plastic substrate layer, and a bottom material layer sequentially arranged side by side; a color film layer, located at one side of an upper surface of the stone-plastic base material part; a first wear-resistant layer, located at one side of an upper surface of the color film layer; and a second wear-resistant layer, located at one side of a lower surface of the stone-plastic base material part; and wherein the middle material layer and the bottom material layer are mainly composed of polyvinyl chloride, dioctyl terephthalate, plasticizer, stabilizer, carbon black, and stone powder.

(47) Thicknesses of the first wear-resistant layer and the second wear-resistant layer are 0.45 mm, and a thickness of the color film layer is 0.45 mm; and a thickness of the stone-plastic substrate layer is 2.75 mm, a thickness of the middle material layer is 1.5 mm, and a thickness of the bottom material layer is 0.05 mm.

(48) Densities of the first wear-resistant layer and the second wear-resistant layer are 1.4 g/cm.sup.3. A density of the stone-plastic substrate layer is 1.95 g/cm.sup.3, a density of the middle material layer is 1.9 g/cm.sup.3, and a density of the bottom material layer is 1.9 g/cm.sup.3.

(49) Parts by weight of polyvinyl chloride, plasticizer, stabilizer, carbon black, and stone powder in the middle material layer are 100:37.5:3.5:1.25:450.

(50) Parts by weight of polyvinyl chloride, plasticizer, stabilizer, carbon black, and stone powder in the bottom material layer are 100:30:3.5:1.25:150.

(51) The manufacturing process thereof includes the following steps: 1) adding raw materials of a bottom material layer according to the above-mentioned formula ratio and mixing the raw materials to obtain a bottom material layer intermediate, and then internal-mixing and calendering the bottom material layer intermediate to obtain a bottom material layer sheet; 2) adding raw materials of a middle material layer according to the above-mentioned formula ratio and mixing the raw materials to obtain a middle material layer intermediate, and then internal-mixing and calendering the middle material layer intermediate to obtain a middle material layer sheet; 3) mixing, internal-mixing, calendering, and slicing raw materials of the stone-plastic substrate layer to obtain a stone-plastic substrate layer sheet; and 4) sequentially arranging a first wear-resistant layer film, a color film, the middle material layer sheet, the stone-plastic substrate layer sheet, the bottom material layer sheet, and a second wear-resistant layer film, and then carrying out a hot pressing process to obtain a finished product.

(52) In the hot pressing process, a pressure is controlled at 4.5 MPa, a temperature is controlled at 135° C., and hot pressing time is controlled at 1800 s.

(53) The cold pressing process includes a first cold pressing process and a second cold pressing process. In the first cold pressing process, a pressure is controlled at 6.5 MPa, a temperature is controlled at 112.5° C., and cold pressing time is controlled at 700 s. In the second cold pressing process, a pressure is controlled at 11.5 MPa, a temperature is controlled at 51.5° C., and cold pressing time is controlled at 900 s.

(54) TABLE-US-00004 Project name Stone-plastic hot pressing hardness 63 HD expansion rate at 50° C. 0.12% contraction rate at 80° C. 0.75% warpage at 80° C. 0.3 mm mute value 70 decibels

Comparative Example One

(55) A stone-plastic hot pressing floor includes a stone-plastic base material part, and the stone-plastic base material part includes a middle material layer, a stone-plastic substrate layer, and a bottom material layer sequentially arranged side by side; a color film layer, located at one side of an upper surface of the stone-plastic base material part; a first wear-resistant layer, located at one side of an upper surface of the color film layer; and a second wear-resistant layer, located at one side of a lower surface of the stone-plastic base material part; and wherein the middle material layer and the bottom material layer are mainly composed of polyvinyl chloride, dioctyl terephthalate, plasticizer, stabilizer, carbon black, and stone powder.

(56) Thicknesses of the first wear-resistant layer and the second wear-resistant layer are 0.85 mm, and a thickness of the color film layer is 0.85 mm; and a thickness of the stone-plastic substrate layer is 4.1 mm, a thickness of the middle material layer is 1.9 mm, and a thickness of the bottom material layer is 1.7 mm.

(57) Densities of the first wear-resistant layer and the second wear-resistant layer are 1.25 g/cm.sup.3. A density of the stone-plastic substrate layer is 3.4 g/cm.sup.3, a density of the middle material layer is 1.8 g/cm.sup.3, and a density of the bottom material layer is 1.8 g/cm.sup.3.

(58) Parts by weight of polyvinyl chloride, plasticizer, stabilizer, carbon black and stone powder in the middle material layer are 100:42:7:3:600.

(59) Parts by weight of polyvinyl chloride, plasticizer, stabilizer, carbon black and stone powder in the bottom material layer are 100:37:7:3:300.

(60) The manufacturing process thereof includes the following steps: 1) adding raw materials of a bottom material layer according to the above-mentioned formula ratio and mixing the raw materials to obtain a bottom material layer intermediate, and then internal-mixing and calendering the bottom material layer intermediate to obtain a bottom material layer sheet; 2) adding raw materials of a middle material layer according to the above-mentioned formula ratio and mixing the raw materials to obtain a middle material layer intermediate, and then internal-mixing and calendering the middle material layer intermediate to obtain a middle material layer sheet; 3) mixing, internal-mixing, calendering, and slicing raw materials of the stone-plastic substrate layer to obtain a stone-plastic substrate layer sheet; and 4) sequentially arranging a first wear-resistant layer film, a color film, the middle material layer sheet, the stone-plastic substrate layer sheet, the bottom material layer sheet, and a second wear-resistant layer film, and then carrying out a hot pressing process to obtain a finished product.

(61) In the hot pressing process, a pressure is controlled at 6.0 MPa, a temperature is controlled at 160° C., and hot pressing time is controlled at 2300 s.

(62) The cold pressing process includes a first cold pressing process and a second cold pressing process. In the first cold pressing process, a pressure is controlled at 9 MPa, a temperature is controlled at 155° C., and cold pressing time is controlled at 900 s. In the second cold pressing process, a pressure is controlled at 17 MPa, a temperature is controlled at 90° C., and cold pressing time is controlled at 1200 s.

(63) The product performance of the common stone-plastic flooring in the existing market:

(64) TABLE-US-00005 Project name Stone-plastic hot pressing hardness 63 HD expansion rate at 50° C. 0.20% contraction rate at 80° C. 1.21% warpage at 80° C. 0.5 mm mute value 90 decibels

(65) The product performance of the existing stone-plastic flooring on the market is:

(66) TABLE-US-00006 Project name Stone-plastic hot pressing hardness 75 HD expansion rate at 50° C. 0.32% contraction rate at 80° C. 1.75% warpage at 80° C. 0.7 mm mute value 105 decibels

(67) To sum up, it can be seen from Embodiment One and Embodiment Two that, by using the technology within the process scope, the density of the obtained hot pressing stone-plastic flooring is lower than that of the existing product, and the hardness is lower than that of the existing product; while the expansion rate at 50, the contraction rate at 80° C. and the mute value are much lower than those of the existing products, making the product yield greatly improved.

(68) From comparative Example One, it can be seen that, when exceeding the process scope in Embodiment One and Two, the hardness, the expansion rate at 50° C., the contraction rate at 80° C. and the warpage at 80° C. are more closer to those of the existing products, which is far more behind the product performance in Embodiment One, Embodiment Two, and Embodiment Three.

(69) The above description are only preferred embodiments of the present invention, and thus does not limit the scope of patent protection of the present invention. Any equivalent structural transformation made by using the contents of the specification of the present invention or directly or indirectly applying the present invention to other related technical fields is included in the scope of protection of the present invention.