Composite floor and manufacturing method thereof

Abstract

A composite flooring and a manufacturing method thereof are disclosed. The composite floor includes, at least, a bamboo-plate surface layer and an organic layer.

Claims

1. A composite floor, characterized at least comprising a bamboo-plate surface layer and an organic layer; the organic layer is a bamboo plastic layer, and the bamboo plastic layer comprises the following components by weight: 100 parts of polyvinyl chloride, 30 to 50 parts of silane coupling agent modified bamboo powder, 30 to 50 parts of calcium carbonate, 5 to 7 parts of sterilizer, 10 to 16 parts of foam regulator, 0.8 to 1.6 parts of foaming agent, 2 to 4 parts chlorinated polyethylene, 3 to 5 parts of lubricant, 1 to 3 parts of plasticizer, and 0.2 to 0.6 parts of anti-aging agent.

2. The composite floor according to claim 1, characterized in that a soft wood or fireproof plate bottom layer is arranged below the organic layer; the soft wood layer is a sawdust laminated layer or a soft wood EVA foaming material layer; the bamboo-plate surface layer is 1 to 3 mm thick and has a moisture rating of 5 to 15%; and the organic layer is 4 to 10 mm thick.

3. The composite floor according to claim 1, characterized in that the sterilizer is calcium stearate; the foaming agent is azodicarbonamide; the plasticizer is dimethyl phthalate, diethyl phthalate or di-n-octyl phthalate.

4. The composite floor according to claim 3, characterized in that an adhesive layer is arranged between the bamboo-plate surface layer and the organic layer; and the surface of the bamboo-plate surface layer is provided with a bamboo plastic layer having a seal coat.

5. The composite floor according to claim 4, characterized in that the adhesive layer is a polyurethane glue layer.

6. The composite floor according to claim 5, characterized in that the glue consists of the following raw materials by weight: 70 to 95 parts of polyurethane, 25 to 35 parts of phthalic anhydride, 10 to 12 parts of triethylene glycol, 15 to 18 parts of glutaric acid, 8 to 10 parts of butanetriol, 5 to 7 parts of zinc oxide, 3 to 5 parts of magnesium oxide, 15 to 25 parts of chloroprene rubber, 2 to 3 parts of softening oil; 15 to 20 parts of dimethyl carbonate, 20 to 30parts of ethylbenzene and 1 to 3 parts of fire retardant; the fire retardant consist of the following components by weight part: 20 to 50 parts of ammonium oligomericphosphate, 10 to 25 parts of ammonium phosphate, 6 to 12 parts of ammonium pyrophosphate, 5 to 20 parts of ammonium sulfate, 5 to 10 parts of boric acid and 10 to 25 parts of water.

Description

DETAILED DESCRIPTION OF THE INVENTION

(1) Embodiment 1

(2) The composite floor is a bamboo plastic composite floor, at least including a bamboo-plate surface layer, a bamboo plastic layer and an adhesive layer located between the bamboo-plate surface layer and the bamboo plastic layer.

(3) Manufacturing Method of the Bamboo Plastic Layer:

(4) (1) modification: bamboo powder with a particle size of 60 to 120 m and silane coupling agent which accounts for 1.1% of the organic powder by weight are uniformly mixed and stirred at a temperature of 100 degrees C., then cooled to 5 degrees C. to obtain modified bamboo powder

(5) (2) material mixing in a weight ratio: 100 parts of polyvinyl chloride, 30 parts of calcium carbonate, 5 parts of sterilizer, 10 parts of foam regulator, 0.8 part of foaming agent, 2 parts of chlorinated polyethylene, 3 parts of lubricant, 1 part of plasticizer, 0.2 part of anti-aging agent and 30 to 50 parts of silane coupling agent modified organic powder are mixed and stirred at a speed of 600 revolutions per minute for 20 min at a temperature of 110 degrees C. to obtain a mixed material, wherein the sterilizer is calcium stearate; the foaming agent is azodicarbonamide; the plasticizer is dimethyl phthalate, diethyl phthalate or di-n-octyl phthalate; the foam regulator is an acrylic foam regulator; the lubricant is a fatty acid type mixer; and the anti-aging agent is a quinine type radical scavenger.

(6) (3) extrusion molding: the mixed material is fed into the barrel of a main conical double-screw extruder, and the extruder is started at the same time to extrude and mold a bamboo plastic material with a density of 600 to 800 kg/cm.sup.3, wherein the main extruder for extrusion and molding has a temperature of 130 degrees C., a rotation speed of 40 revolutions per minute and an extrusion speed of 600 mm/min; the melt pressure of the extruder is 3 Mpa; the rotation speed of the feeding machine is 4 revolutions per minute; and the temperature of the machine head is 160 degrees C.;

(7) (4) post processing: the molded bamboo plastic material water cooled, drawn and cut to obtain the bamboo plastic plate substrate.

(8) Manufacturing method of the bamboo-plate surface layer: the bottom surface of the bamboo-plate surface layer is sanded with a 120 to 150 m sanding belt to be smooth.

(9) Preparation of the Polyurethane Glue: the Following Components are Mixed by Weight:

(10) 70 parts of polyurethane, 25 parts of phthalic anhydride, 10 parts of triethylene glycol, 15 parts of glutaric acid, 8 parts of butanetriol, 5 parts of zinc oxide, 3 parts of magnesium oxide, 15 parts of chloroprene rubber, 2 parts of softening oil; 15 parts of dimethyl carbonate, 20 parts of ethylbenzene and 3 parts of fire retardant; the fire retardant consist of the following components by weight: 20 parts of ammonium oligomericphosphate, 10 parts of ammonium phosphate, 6 parts of ammonium pyrophosphate, 5 parts of ammonium sulfate, 10 parts of boric acid and 25 parts of water.

(11) Manufacturing of the composite floor: the sanded bamboo-plate surface layer is cold pressed to the bamboo plastic layer using the polyurethane glue at a temperature of 5 degrees C. under a pressure of 1 MPa/cm.sup.2. Finally, manufacturing of the seal coat on the surface of the bamboo-plate surface layer: the surface of the bamboo-plate surface layer is colored first; then the floor is heated to 30 degrees C., next a primer is sprayed to the colored surface of the bamboo-plate surface layer; and finally, a varnish is applied onto the primer surface after the primer has dried. The bamboo-plate surface layer of the finally obtained composite floor is 2 mm thick and has a moisture rating of 10%, and the bamboo plastic layer is 7 mm thick.

(12) Embodiment 2

(13) The composite floor is a bamboo plastic composite floor, at least including a bamboo-plate surface layer, a bamboo plastic layer and an adhesive layer located between the bamboo-plate surface layer and the bamboo plastic layer.

(14) Manufacturing Method of the Bamboo Plastic Layer:

(15) (1) modification: the bamboo powder with a particle size of 60 to 120 m and silane coupling agent which accounts for 1.3% of the organic powder by weight are uniformly mixed and stirred at a temperature of 130 degrees C., then cooled to 45 degrees C. to obtain modified bamboo powder;

(16) (2) material mixing in a weight ratio:100 parts of polyvinyl chloride, 50 parts of calcium carbonate, 7 parts of sterilizer, 16 parts of foam regulator, 1.6 parts of foaming agent, 4 parts of chlorinated polyethylene, 5 parts of lubricant, 3 parts of plasticizer, 0.6 part of anti-aging agent and 30 to 50 parts of silane coupling agent modified organic powder are mixed and stirred at a temperature of 130 degrees C. for 30 min to obtain a mixed material, wherein the stirring speed is 1,000 revolutions per minute;

(17) (3) extrusion molding: the mixed material is fed into the barrel of a main conical double-screw extruder, and the extruder is started at the same time to extrude and mold a bamboo plastic material with a density of 1,200 kg/cm3, wherein the main extruder for extrusion and molding has a temperature of 170 degrees C., a rotation speed of 50 revolutions per minute and an extrusion speed of 600 mm/min; the melt pressure of the extruder is 8 Mpa; the rotation speed of the feeding machine is 6 revolutions per minute; and the temperature of the machine head is 170 degrees C.;

(18) (4) post processing: the molded organic material is water cooled, drawn and cut to obtain the organic plate substrate.

(19) Manufacturing method of the bamboo-plate surface layer: the bottom surface of the bamboo-plate surface layer is sanded with a 120 to 150 m sanding belt to be smooth.

(20) Preparation of the Polyurethane Glue: the Following Components are Mixed by Weight:

(21) 80 parts of polyurethane, 35 parts of phthalic anhydride, 12 parts of triethylene glycol, 18 parts of glutaric acid, 10 parts of butanetriol, 7 parts of zinc oxide, 5 parts of magnesium oxide, 25 parts of chloroprene rubber, 3 parts of softening oil; 20 parts of dimethyl carbonate, 30 parts of ethylbenzene and 1 part of fire retardant; the fire retardant consist of the following components by weight: 50 parts of ammonium oligomericphosphate, 25 parts of ammonium phosphate, 12 parts of ammonium pyrophosphate, 20 parts of ammonium sulfate, 5 parts of boric acid and 10 parts of water.

(22) Manufacturing of the composite floor: the sanded bamboo-plate surface layer is cold pressed to the bamboo plastic layer using polyurethane glue at a temperature of 60 degrees C. under a pressure of 3 MPa/cm.sup.2. Finally, manufacturing of the seal coat on the surface of the bamboo-plate surface layer: the surface of the bamboo-plate surface layer is colored first; then the floor is heated to 38 degrees C., next a primer is sprayed to the colored surface of the bamboo-plate surface layer; and finally, a varnish is applied onto the primer surface after the primer has dried. The bamboo-plate surface layer of the finally obtained composite floor is 1 mm thick and has a moisture rate of 5%, and the bamboo plastic layer is 4 mm thick.

(23) Embodiment 3

(24) The composite floor is a bamboo plastic composite floor, at least including a bamboo-plate surface layer, a bamboo plastic layer and an adhesive layer located between the bamboo-plate surface layer and the bamboo plastic layer.

(25) Manufacturing Method of the Bamboo Plastic Layer:

(26) (1) modification: the bamboo powder with a particle size of 60 to 120 m and silane coupling agent which accounts for 1.2% of the organic powder by weight are uniformly mixed and stirred at a temperature of 120 degrees C., then cooled to 25 degrees C. to obtain modified bamboo powder;

(27) (2) material mixing in a weight ratio: 100 parts of polyvinyl chloride, 40 parts of calcium carbonate, 6 parts of sterilizer, 12 parts of foam regulator, 1.2 parts of foaming agent, 3 parts of chlorinated polyethylene, 4 parts of lubricant, 2 parts of plasticizer,0.4 part of anti-aging agent and 30 to 50 parts of silane coupling agent modified organic powder are mixed and stirred at a temperature of 120 degrees C. for 26 min to obtain a mixed material, wherein the stirring speed is 800 revolutions per minute;

(28) (3) extrusion molding: the mixed material is fed into the barrel of a main conical double-screw extruder, and the extruder is started at the same time to extrude and mold a bamboo plastic material with a density of 800 to 1,000 kg/cm.sup.3, wherein the main extruder for extrusion and molding has a temperature of 150 degrees C., a rotation speed of 45 revolutions per minute and an extrusion speed of 800 mm/min; the melt pressure of the extruder is 5 Mpa; the rotation speed of the feeding machine is 5 revolutions per minute; and the temperature of the machine head is 165 degrees C.;

(29) (4) post processing: the molded organic material is water cooled, drawn and cut to obtain the organic plate substrate.

(30) Manufacturing method of the bamboo-plate surface layer: the bottom surface of the bamboo-plate surface layer is sanded with a 120 to 150 m sanding belt to be smooth.

(31) Preparation of the Polyurethane Glue: the Following Components are Mixed by Weight Part:

(32) 95 parts of polyurethane, 29 parts of phthalic anhydride, 11 parts of triethylene glycol, 16 parts of glutaric acid, 9 parts of butanetriol, 6 parts of zinc oxide, 4 parts of magnesium oxide, 21 parts of chloroprene rubber, 2.5 parts of softening oil; 18 parts of dimethyl carbonate, 26 parts of ethylbenzene and 2 parts of fire retardant; the fire retardant consist of the following components by weight: 30 parts of ammonium oligomericphosphate, 18 parts of ammonium phosphate, 9 parts of ammonium pyrophosphate, 15 parts of ammonium sulfate, 8 parts of boric acid and 18 parts of water.

(33) Manufacturing of the composite floor: the sanded bamboo-plate surface layer is cold pressed to the bamboo plastic layer using the polyurethane glue at a temperature of 30 degrees C. under a pressure of 2 MPa/cm.sup.2. Finally, the manufacturing of the seal coat on the surface of the bamboo-plate surface layer: the surface of the bamboo-plate surface layer is colored first; then the floor is heated to 35 degrees C., next a primer is sprayed to the colored surface of the bamboo-plate surface layer; and finally, a varnish is applied to on the primer surface after the primer has dried. The bamboo-plate surface layer of the finally obtained composite floor is 3 mm thick and has a moisture rating of 15%, and the bamboo plastic layer is 10 mm thick.

(34) Embodiment 4

(35) Similar to embodiment 1, different in that the composite floor is a wood plastic composite floor

(36) Embodiment 5

(37) Similar to embodiment 2, different in that the composite floor is a wood plastic composite floor

(38) Embodiment 6

(39) Similar to embodiment 1, different in that the composite floor is a wood plastic composite floor

(40) Embodiment 7

(41) Similar to embodiment 1, different in that: in step (1), the organic powder with a particle size of 60 to 120 m and the silane coupling agent which accounts for 1.1% of the organic powder by weight are uniformly mixed and stirred at a speed of 1,000 revolutions per minute for 5 min at temperature of 100 degrees C., then kept at this temperature for 2 min, next cooled to 5 degrees C. to obtain the modified organic powder.

(42) In step (2), materials mixing comprises stirring and mixing the foam regulator, the foaming agent, the lubricant, the plasticizer, the anti-aging agent and the modified organic powder obtained in step (1) in a stirring mixer at a temperature of 110 degrees C. for 15 min, then adding the polyvinyl chloride, calcium carbonate, sterilizer and chlorinated polyethylene into the stirring mixer, continuously mixing and stirring for 5 min to obtain the mixed material, wherein the stirring speed is 600 revolutions per minute.

(43) In order to manufacture the composite floor, the bamboo-plate surface layer serving as the surface layer, the bamboo plastic organic layer serving as the core layer and the fireproof plate layer serving as the bottom layer are glued and cold pressed to form the composite floor.

(44) Embodiment 8

(45) Similar to embodiment 2, different in that: in step (1), the organic powder with a particle size of 60 to 120 m and the silane coupling agent which accounts for 1.3% of the organic powder by weight are uniformly mixed and stirred at a speed of 1,300 revolutions per minute for 8 min at temperature of 130 degrees C., then kept at this temperature for 4 min, next cooled to 45 degrees C. to obtain the modified organic powder.

(46) In step (2), material mixing comprises stirring and mixing the foam regulator, the foaming agent, 3 to 5 parts of the lubricant, the plasticizer, the anti-aging agent and the modified organic powder obtained in step (1) in a stirring mixer at a temperature of 130 degrees C. for 20 min, then adding the polyvinyl chloride, calcium carbonate, sterilizer and chlorinated polyethylene into the stirring mixer, continuously mixing and stirring for 10 min to obtain the mixed material, wherein the stirring speed is 1,000 revolutions per minute.

(47) When manufacturing the composite floor, the bamboo-plate surface layer serving as the surface layer, the bamboo plastic organic layer serving as the core layer and the EVA bottom layer are hot pressed to form the composite floor.

(48) Embodiment 9

(49) Similar to embodiment 3, different in that: in step (1), the organic powder with a particle size of 60 to 120 m and the silane coupling agent which accounts for 1.2% of the organic powder by weight are uniformly mixed and stirred at a speed of 1,200 revolutions per minute for 6 min at temperature of 120 degrees C., then kept at this temperature for 3 min, next cooled to 35 degrees C. to obtain the modified organic powder.

(50) In step (2), material mixing comprises stirring and mixing the foam regulator, the foaming agent, 3 to 5 parts of the lubricant, the plasticizer, the anti-aging agent and the modified organic powder obtained in step (1) in a stirring mixer at a temperature of 110 to 130 degrees C. for 18 min, then adding the polyvinyl chloride, calcium carbonate, sterilizer and chlorinated polyethylene into the stirring mixer, continuously mixing and stirring for 8 min to obtain the mixed material, wherein the stirring speed is 800 revolutions per minute.

(51) When manufacturing the composite floor, the bamboo-plate surface layer serving as the surface layer, the bamboo plastic organic layer serving as the core layer and the sawdust soft wood bottom layer are glued and cold pressed into the composite floor.

(52) Comparative Embodiment 1

(53) Similar to embodiment 1, different in that the bamboo powder is not modified by the silane coupling agent, and the bamboo plastic layer does not include calcium carbonate and chlorinated polyethylene.

(54) Comparative Embodiment 2

(55) Similar to embodiment 2, different in that the bamboo powder is not modified by the silane coupling agent. To manufacture the composite floor, the bottom surface of the bamboo surface layer is sanded with the sanding belt to be smooth and then cold pressed to the bamboo plastic layer using polyurethane glue at a temperature of 70 degrees C. under a pressure of 4 MPa/cm.sup.2.

(56) According to the evaluation standard GB/T18103-2003, the standard value of static bending intensity is more than or equal to 300 MPa; the elasticity modulus is more than or equal to 4,000 MPa; the formaldehyde emission E.sub.0 is less than or equal to 0.5 Mg/L.

(57) Embodiments and comparative embodiment detection results of the present invention are as follows:

(58) TABLE-US-00001 Static Elasticity Formaldehyde bending modulus emission Item intensity MPa Mg/L Soaked in water Embodiment 1 50 8640 0.2 Soaked for 85 days, no expansion, no deformation Embodiment 2 54 8750 0.2 Soaked for 85 days, no expansion, no deformation Embodiment 3 58 8910 0.2 Soaked for 85 days, no expansion, no deformation Embodiment 4 52 8440 0.1 Soaked for 95 days, no expansion, no deformation Embodiment 5 51 8370 0.1 Soaked for 95 days, no expansion, no deformation Embodiment 6 53 8438 0.1 Soaked for 95 days, no expansion, no deformation Embodiment 7 62 8960 0.1 Soaked for 95 days, no expansion, no deformation Embodiment 8 64 8980 0.1 Soaked for 95 days, no expansion, no deformation Embodiment 9 66 9018 0.1 Soaked for 95 days, no expansion, no deformation Comparative 36 7000 0.3 Soaked for 60 days, no Embodiment 1 expansion, no deformation Comparative 38 7400 0.3 Soaked for 65 days, no Embodiment 2 expansion, no deformation

(59) From the above table it can be seen that the bamboo-organic floor, in particular the bamboo-bamboo plastic and/or soft wood or fireproof button layer composite floor has formaldehyde emission of reaching level E.sub.0, almost negligible, and has high static bending intensity and elasticity modulus. This means that the composite floor of the present invention is firmly constructed, resistant to bending, wrapping and deformation, damp-proof and antiseptic.

(60) The specific embodiments are merely used to explain the present invention, and shall not be regarded as expressing the limits of the present invention. Those skilled in this field can make modifications without a creative step after reading this specification. All modifications which fall within the protective scope of claims of the present invention are protected by the Patent Law.