CO-EXTRUSION SPC FOAM FLOORING AND MANUFACTURING METHOD THEREOF

Abstract

A foam flooring includes a stone-plastic base material structure, which sequentially comprises, from top to bottom, a first stable layer, a foaming layer and a second stable layer. The first stable layer and the second stable layer are both sheets with a PVC resin and filler powder as main components, with 25-40 parts by mass of the PVC resin and 55-75 parts by mass of the filler powder; and the density of the SPC foam flooring is 1.4-1.6 g/cm3. The foaming layer is arranged between the two stable layers, such that the overall density of the flooring is significantly reduced and reaches 1.4-1.6 g/m3; since the foaming layer is arranged inside, the surface strength of the overall flooring is not influenced.

Claims

1. A method for manufacturing a stone-plastic flooring, wherein the stone-plastic flooring comprises a stone-plastic base material structure obtained from a stone-plastic base material plate; said stone-plastic base material plate comprising a foam layer; the method comprising: feeding the raw materials for the foaming layer into a high-speed mixer, mixing and heating the raw materials and cooling an obtained mixture of said raw materials; introducing said mixture into an extruder, performing even melt plastification of said mixture in said extruder, injecting liquefied high-pressure carbon dioxide into a foaming agent injection device connected to a mold cavity of said extruder, mixing said carbon dioxide with said mixture at a pressure, releasing the pressure during the course of extrusion to thereby form an extrudate; allowing the extrudate to be extruded through a die head connected to said extruder to form said stone-plastic base material plate; passing the stone-plastic base material plate through rollers.

2. The method of claim 1, wherein said raw materials comprise 100 parts by weight of polyvinyl chloride and 300 parts or more of calcium carbonate.

3. The method of claim 1, wherein said stone plastic flooring has a dimensional change rate as measured in accordance with ISO 23999 of less than 0.13%, or of about 0.08%.

4. The method of claim 1, wherein said stone plastic flooring has a curling after heating as measured in accordance with ISO 23999 of less than 0.77 mm, or of about 0.30 mm.

5. The method of claim 1, wherein said stone plastic flooring has a density as measured in accordance with ISO 23996 of less than 1.984 g/cm.sup.3, of between 1.4 and 1.6 g/cm.sup.3, or of about 1.531 g/cm.sup.3.

6. The method of claim 1, wherein said method further comprises laminating a wear-resistant layer and a decor layer on the stone-plastic base material plate by means of rollers, wherein the decorative layer is a PVC film with a pattern and the wear-resistant layer is a polymer layer with a thickness in the range of 0.1 to 1.0 mm.

7. The method of claim 6, wherein said wear-resistant layer comprises PVC resin as a main component and suitable amounts of plasticizer, lubricant and stabilizer.

8. The method of claim 7, wherein said method further comprises forming a surface pattern with concave and convex three-dimensional effect on a front face of said stone-plastic flooring.

9. The method of claim 1, wherein said method further comprises disposing said foaming layer between two stable layers by converging said extrudate with a second extrudate from a second extruder at said die head.

10. The method of claim 1, wherein said liquefied carbon dioxide is injected at a rate of 4 to 10 wt %.

11. The method of claim 1, wherein said foam layer has a thickness of 2 to 10 mm.

12. The method of claim 1, wherein said stone-plastic base material has a thickness of 4 to 20 mm.

13. The method of claim 7, wherein a UV coating is formed is present as a topmost layer of said stone plastic flooring, wherein said UV coating has a thickness of 30 to 150 m.

14. Method for manufacturing a stone-plastic flooring, wherein the stone-plastic flooring comprises a stone-plastic base material structure obtained from a stone-plastic base material plate; said stone-plastic base material plate comprising a foam layer; the method comprising: feeding the raw materials for the foaming layer into a high-speed mixer, mixing and heating the raw materials and cooling an obtained mixture of said raw materials, wherein said raw materials comprise 100 parts by weight of polyvinyl chloride and 300 parts or more of calcium carbonate; introducing said mixture into an extruder, performing even melt plastification of said mixture in said extruder, injecting liquefied high-pressure carbon dioxide into a foaming agent injection device connected to a mold cavity of said extruder, mixing said carbon dioxide with said mixture at a pressure, releasing the pressure during the course of extrusion to thereby form an extrudate; allowing the extrudate to be extruded through a die head connected to said extruder to form said stone-plastic base material plate; passing the stone-plastic base material plate through rollers; laminating a wear-resistant layer and a decor layer on the stone-plastic base material plate by means of rollers, wherein the decorative layer is a PVC film with a pattern and the wear-resistant layer is a polymer layer with a thickness in the range of 0.1 to 1.0 mm, wherein said wear-resistant layer comprises PVC resin as a main component and suitable amounts of plasticizer and stabilizer; forming a surface pattern with concave and convex three-dimensional effect on a front face of said stone-plastic flooring; providing a UV coating as a topmost layer of said stone plastic flooring.

15. The method of claim 14, wherein said stone plastic flooring has a dimensional change rate as measured in accordance with ISO 23999 of less than 0.13%, or of about 0.08%.

16. The method of claim 14, wherein said stone plastic flooring has a curling after heating as measured in accordance with ISO 23999 of less than 0.77 mm, or of about 0.30 mm.

17. The method of claim 14, wherein said stone plastic flooring has a density as measured in accordance with ISO 23996 of less than 1.984 g/cm.sup.3, of between 1.4 and 1.6 g/cm.sup.3, or of about 1.531 g/cm.sup.3.

18. The method of claim 14, wherein said method further comprises disposing said foaming layer between two stable layers by converging said extrudate with a second extrudate from a second extruder at said die head.

19. The method of claim 14, wherein said liquefied carbon dioxide is injected at a rate of 4 to 10 wt %.

20. The method of claim 14, wherein said foam layer has a thickness of 2 to 10 mm, and said stone-plastic base material has a thickness of 4 to 20 mm.

21. The method of claim 14, wherein said UV coating has a thickness of 30 to 150 m.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0030] FIG. 1 shows a schematic diagram indicating the structure of the present invention;

[0031] FIG. 2 is a schematic diagram indicating the device of the present invention;

[0032] FIG. 3 is a schematic diagram indicating the device according to Example 1 of the present invention; wherein, 1UV coating, 2wear-resistant layer, 3decorative layer, 4first stable layer, 5foaming layer, 6second stable layer, 10background pattern roller, 20first mirror finish roller; 30second mirror finish roller, 40embossing roller, 200the servo feeding roller for the wearresistant layer, 300the servo feeding roller for the decorative layer, 400air release roller.

MOST PREFERRED EMBODIMENT FOR CARRYING OUT THE INVENTION

[0033] As shown in FIG. 1, a co-extrusion SPC foam flooring comprises a decorative and protective structure and a stone-plastic base material structure.

[0034] The decorative and protective structure sequentially comprises, from top to bottom, a UV coating (1), a wear-resistant layer (2) and a decorative layer (3); the stone-plastic base material structure sequentially comprises, from top to bottom, a first stable layer (4), a foaming layer (5), and a second stable layer (6). The density of the SPC foam flooring is 1.531 g/cm.sup.3.

[0035] In this Example, the thickness of the UV coating (1) is 100 m.

[0036] The wear-resistant layer (2) comprises a PVC resin as a main component and is obtained by the calendering process after the addition of suitable amounts of plasticizer, lubricant and stabilizer. Its thickness is 0.3 mm.

[0037] The decorative layer (3) is a PVC film with surface pattern. Its thickness is 0.07 mm.

[0038] The first stable layer (4) and the second stable layer (6) are both sheets with a PVC resin and filler powder as main components; wherein the amount of the PVC resin is 100 parts by weight, the filler powder is calcium carbonate with an amount of 250 parts by weight, and additives comprising the following components in parts by weight are added: [0039] 5 parts of a calcium zinc stabilizer [0040] part of an internal lubricant [0041] 1.4 parts of polyethylene wax [0042] 5 parts of chlorinated polyethylene [0043] 2 parts of acrylate [0044] parts of a composite lubricant [0045] 0.5 parts of a colorant

[0046] The aforesaid auxiliary agents are conventional auxiliary agents in the art, so there is no need to go into details.

[0047] The foaming layer (5) is a chemical foaming layer comprising the following components in parts by weight: [0048] 100 parts of PVC resin powder [0049] 160 parts of calcium carbonate [0050] 6 parts of a calcium zinc stabilizer [0051] 0.8 parts of a foaming agent [0052] 0.6 parts of polyethylene wax [0053] 2 parts of chlorinated polyvinyl chloride [0054] 2 parts of acrylate [0055] 0.5 parts of a lubricant [0056] 7 parts of a foaming regulator [0057] 0.5 part of a colorant

[0058] The aforesaid auxiliary agents are conventional auxiliary agents in the art, so there is no need to go into details.

[0059] As shown in FIG. 2, the method for preparing the SPC foam flooring of this Example is as follows: [0060] a. The raw materials for the first stable layer (4) and the second stable layer (6) are fed into the high-speed mixer, mixed and heated, cooled in the low-speed mixer, and are extruded from the extruder A; [0061] b. The raw materials for the foaming layer (5) are fed into the high-speed mixer, mixed and heated, cooled under low-speed stirring, introduced into the extruder B, subjected to melt plastification and are extruded from the extruder B; [0062] c. The extrudate of the extruder A is allowed to enter the mold flow channel distributor and converge with the extrudate of the extruder B at the die head, and the mixture is co-extruded through the die orifice of the die head to form the stone-plastic base material structure; [0063] d. The plate released from the mold is passed through an area between the background pattern roller (10) and the first mirror finish roller (20) to form the background pattern by compression, the stone-plastic base material structure is transferred to an area between the second mirror finish roller (30) and the embossing roller (40); the wear-resistant layer and the decorative paper are transferred by the servo feeding roller for the wear-resistant layer (200) and the servo feeding roller for the decorative layer (300) to an area between the second mirror finish roller (30) and the air release roller (400), and are subjected to pre-lamination; the wear-resistant layer and the decorative paper are laminated on the base material layer through the action of the second mirror finish roller (30) and the embossing roller (40) to form the wear-resistant layer and the decorative layer, as well as a surface pattern with concave and convex three-dimensional effect on the front face.

[0064] The properties comparison between the most preferred embodiment and conventional stone-plastic flooring (without foaming) is shown in the Table below.

TABLE-US-00001 Test results Co-extrusion ABA ABA foam stone-plastic Test stone-plastic flooring (most Test item standard flooring preferred embodiment) Dimensional ISO 0.13% 0.08% change rate 23999 after heating Curling after ISO 0.77 mm 0.30 mm heating 23999 Density ISO 1.984 g/cm.sup.3 1.531 g/cm.sup.3 23996

EMBODIMENTS OF THE INVENTION

[0065] As shown in FIG. 1, a co-extrusion SPC foam flooring comprises a decorative and protective structure and a stone-plastic base material structure.

[0066] The decorative and protective structure sequentially comprises, from top to bottom, a UV coating (1), a wear-resistant layer (2) and a decorative layer (3); the stone-plastic base material structure sequentially comprises, from top to bottom, a first stable layer (4), a foaming layer (5), and a second stable layer (6). The density of the SPC foam flooring is 1.465 g/cm.sup.3.

[0067] In this Example, the thickness of the UV coating (1) is 100 m.

[0068] The wear-resistant layer (2) comprises a PVC resin as a main component and is obtained by the calendering process after the addition of suitable amounts of plasticizer, lubricant and stabilizer. Its thickness is 0.3 mm.

[0069] The decorative layer (3) is a PVC film with surface pattern. Its thickness is 0.07 mm.

[0070] The first stable layer (4) and the second stable layer (6) are both sheets with a PVC resin and filler powder as main components; wherein the amount of the PVC resin is 100 parts by weight, the filler powder is calcium carbonate with an amount of 250 parts by weight, and additives comprising the following components in parts by weight are added: [0071] 5 parts of a calcium zinc stabilizer [0072] part of an internal lubricant [0073] 1.4 parts of polyethylene wax [0074] 5 parts of chlorinated polyethylene [0075] 2 parts of acrylate [0076] parts of a composite lubricant [0077] 0.5 parts of a colorant

[0078] The aforesaid auxiliary agents are conventional auxiliary agents in the art, so there is no need to go into details.

[0079] The foaming layer (5) is a physical foaming layer comprising the following components in parts by weight: [0080] 100 parts of polyvinyl chloride resin powder [0081] 330 parts of calcium carbonate [0082] 5.5 parts of a calcium zinc stabilizer [0083] part of an internal lubricant [0084] 1 parts of polyethylene wax [0085] 5.5 parts of chlorinated polyethylene [0086] 3 parts of acrylate [0087] parts of a composite lubricant

[0088] The aforesaid auxiliary agents are conventional auxiliary agents in the art, so there is no need to go into details.

[0089] As shown in FIG. 3, the method for preparing the SPC foam flooring of this Example is as follows: [0090] a. The raw materials for the first stable layer (4) and the second stable layer (6) are fed into the high-speed mixer, mixed and heated, cooled under low-speed stirring, and are extruded from the extruder A; [0091] b. The raw materials for the foaming layer (5) are fed into the high-speed mixer, introduced into the extruder B, mixed and heated, cooled under low-speed stirring, subjected to even melt plastification in the extruder B; 6 wt % liquefied high-pressure carbon dioxide is injected into the foaming agent injection device, a high pressure is maintained in the mold cavity to keep carbon dioxide in a liquid state so as to completely mix with the material, and the pressure is released during the course of extrusion; [0092] c. The extrudate of the extruder A is allowed to enter the mold flow channel distributor and converge with the extrudate of the extruder B at the die head, and the mixture is co-extruded through the die orifice of the die head to form the stone-plastic base material structure; [0093] d. The plate released from the mold is passed through an area between the background pattern roller (10) and the first mirror finish roller (20) to form the background pattern by compression, the stone-plastic base material structure is transferred to an area between the second mirror finish roller (30) and the embossing roller (40); the wear-resistant layer and the decorative paper are transferred by the servo feeding roller for the wear-resistant layer (200) and the servo feeding roller for the decorative layer (300) respectively to an area between the second mirror finish roller (30) and the air release roller (400), and are subjected to pre-lamination; the wear-resistant layer and the decorative paper are laminated on the base material layer through the action of the second mirror finish roller (30) and the embossing roller (40) to form the wear-resistant layer and the decorative layer, as well as a surface pattern with concave and convex three-dimensional effect on the front face.