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CN109906295A - 尺寸稳定的地板镶板 - Google Patents

尺寸稳定的地板镶板 Download PDF

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Publication number
CN109906295A
CN109906295A CN201780064192.4A CN201780064192A CN109906295A CN 109906295 A CN109906295 A CN 109906295A CN 201780064192 A CN201780064192 A CN 201780064192A CN 109906295 A CN109906295 A CN 109906295A
Authority
CN
China
Prior art keywords
parts
polyvinyl chloride
base section
floor panel
amount
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
CN201780064192.4A
Other languages
English (en)
Inventor
灏·阿兰·陈
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Novalis Holding Ltd
Original Assignee
Novalis Holding Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Novalis Holding Ltd filed Critical Novalis Holding Ltd
Priority to CN202411718978.1A priority Critical patent/CN119531565A/zh
Publication of CN109906295A publication Critical patent/CN109906295A/zh
Pending legal-status Critical Current

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Classifications

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    • E04F15/10—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials
    • E04F15/107—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials composed of several layers, e.g. sandwich panels
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Abstract

提供地板镶板。地板镶板的组合物包括耐磨层(14)和基部层。基部层包括第一基部区段(22)、第二基部区段(24)、以及玻璃纤维区段(28)，第一基部区段具有聚氯乙烯、填料和增塑剂的第一组合物，第二基部区段具有比第一组合物更高含量的聚乙烯和增塑剂的第二组合物，玻璃纤维区段位于第一基部区段和第二基部区段之间。

Description

尺寸稳定的地板镶板
交叉引用相关申请
本申请要求2016年10月17日提交的美国临时专利申请No.62/408,998的基于35U.S.C§119(a)-(d)的申请日的权益。
技术领域
本发明总体上涉及一种地板镶板，更具体地，涉及一种尺寸稳定的地板镶板的组合物，该地板镶板的组合物具有带有引导边缘的增强层。
背景技术
豪华乙烯基瓷砖(“LVT”)通常是众所周知的并且是相当受欢迎的地板选择。只要自然外观可以通过轮转凹版打印、数字打印和许多其他方式打印在薄膜上，LVT可以制造成具有木材、石材、板岩、砖、陶瓷或许多其他设计的自然外观。地板的设计具有耐磨的乙烯基地板的弹性和耐用性。虽然在安装LVT期间通常使用粘合剂和锁定体系，但考虑到安装期间的简单性和效率，松散浮动安装已经变得更加流行。
松散铺设瓷砖(“LLT”)产品简单地放置在地板或底层地板上并紧贴地安装在壁上。LLT在特征上需要一些关键特征：(1)较低的膨胀和收缩系数，(2)厚重的玻璃纤维面纱，该厚重的玻璃纤维面纱能提供最佳的尺寸稳定性和固定布置，(3)平整度，该平整度能生成如整体地板片材的大型安装地板的视觉，和(4)防滑背衬，该防滑背衬进一步改善其固定布置。然而，即使具有优异的平整度特性，变形通常也是由于包装和储存期间的无意错误造成的。边缘竖起和卷曲问题通常会发生，并且在运输过程中会更加突出，特别是在寒冷气候的条件下。这些问题不仅是视觉上令人不悦、令人讨厌的因素，而且它们还会影响安装。由于解决方案耗时且成本高，除了保持卷曲之外，没有任何其他好处。
发明内容
因此，本发明是鉴于上述问题而设计的，以提供一种尺寸稳定的地板镶板的组合物，该地板镶板的组合物具有带引导边缘的增强层。
因此，需要形成一种克服边缘竖起或卷曲的方法，该边缘竖起或卷曲不是由产品本身导致而是由包装和运输的复杂环境导致。提供地板镶板。地板镶板的组合物包括耐磨层和基部层。基部层包括第一基部区段、第二基部区段、以及玻璃纤维区段，第一基部区段具有聚氯乙烯、填料和增塑剂的第一组合物，第二基部区段具有比第一组合物更高含量的聚乙烯和增塑剂的第二组合物，玻璃纤维区段位于第一基部区段和第二基部区段之间。此外，突起设置在基部层的一侧上并向外延伸超过顶层。
附图说明
参考附图，将参考实施例更详细地解释本发明，其中：
图1是根据本发明的尺寸稳定的地板镶板的顶部透视图；
图2是图1的尺寸稳定的地板镶板的底部透视图；
图3是图1的地板镶板的示意图，示出了地板镶板的多个层；
图4是图1的沿线4-4截取的地板镶板的剖视图；
图5是图1的地板镶板的部分5的近视图；
图6是根据本发明的相邻地板镶板的示意图；和
图7是根据本发明的连接相邻地板镶板的示意图。
具体实施方式
现在将讨论涉及地板覆盖物、壁纸或具有均匀单层或异质多层结构的其他表面覆盖物的表面覆盖物。地板覆盖物的示例性实施例包括松散放置的豪华乙烯基瓷砖和木板(“LLT”)以及片材地板。然而，本领域普通技术人员将理解，表面覆盖物还可以包括其他类型的覆盖物，例如地毯背衬、壁覆盖物、半刚性挤出片材、乙烯基衬垫、以及弹性硬表面地板，例如乙烯基组合物瓷砖、镶嵌产品以及衬垫地板。
现在参考附图，其中在几个视图和实施例中相同的附图标记表示相同的部件。
在图中所示的实施例中，单个地板镶板1由层压的聚合物部件制成。每个地板镶板1由层压的聚合物部件制成，层压的聚合物部件包括形成若干层的乙烯基。在所示实施例中，每个地板镶板的总厚度约为3.00-5.00mm。然而，也可以制备具有一层或多层的地板镶板1，每层具有不同的厚度。地板镶板1的组合物也可以变化，地板镶板1由各种材料制成，包括但不限于聚合物、陶瓷、金属、有机材料等。
然而，如图1-4所示，地板镶板1被制备为具有挠性聚合物片材材料的顶层10、稳定的聚合物材料的基部层20和由防滑聚合物材料制备的背衬层30。如图所示，层10、20和30中的每一个具有不同的厚度。但是，各层可以具有相同厚度。整个地板镶板1的厚度、分层和制备将符合成品的参数选择，包括尺寸。制造不是针对一个特定的设计，而是包含以下段落中描述的新颖设计特征。
此外，某些实施例可包括共聚物、润滑剂、填料、颜料或其组合。组合物成分的量表示为聚合物重量的每百份份数(“phr”)。
根据本发明，地板镶板1可以成形为正方形或矩形，具有四个边a，b，c，d，其中每个边通过90°的内角(直角)连接。另外，地板镶板1包括顶侧2和底侧4。在所示的实施例中，顶侧2由顶层10制备，底侧4使用背衬层30制备。
如图1-4所示，地板镶板由多个层压板部件制成。在所示的实施例中，顶层10被制备成具有三个部件：薄涂层12、耐用耐磨层14和打印层16，打印层16具有打印特征。任何组件，例如薄涂层12、耐用耐磨层14或打印层16，可以具有纹理，以增强地板镶板1结构的特征。
薄涂层12和耐用耐磨层14设置在打印层16的顶部，并且在所示实施例中，薄涂层12和耐用耐磨层14是透明的，由具有较高耐久性的塑料材料制备。
在所示的实施例中，打印层16设置有打印图案，打印层16的下侧粘合到基部层20，打印图案背离背衬层30。顶层10提供图形和纹理浮雕，并可以制备成匹配任何打印的甚至仿制的真正的变质岩特征。
尽管不是必需的，但薄涂层12可以是厚度约为0.03mm的聚氨酯涂层。然而，就整个地板镶板1结构而言，可以改变薄涂层12的应用、组合物和厚度。
在所示实施例中，顶层10还包括透明的耐磨层14。耐磨层14可由聚氯乙烯或其他聚合物材料，如聚丙烯，制备。耐磨层14用于保护打印层16。并且由于耐磨层14是透明的或清澈的，因此通过耐磨层14可以看到打印层16上的任何美学印记。虽然厚度可以变化，但是磨损层14的厚度的范围为0.1-1.5mm。在所示实施例中，耐磨层14具有约0.50mm的厚度。然而，非常类似于涂层12，可以根据整个地板镶板1结构来制备耐磨层14的应用、组合物和厚度。
在本发明的一个实施例中，耐磨层14的组合物包括聚氯乙烯和增塑剂。聚氯乙烯的K值优选在60-70的范围中。增塑剂优选为非邻苯二甲酸酯型增塑剂，如DOTP、DINCH和生物基增塑剂(即，十八烷酸、10-氯-9-甲氧基-甲酯等)。耐磨层14还可包括稳定剂，稳定剂优选为非重金属含量型稳定剂。例如，可以使用钙/硬脂酸盐和/或硬脂酸锌或钙/锌组合复合皂体系。此外，耐磨层14还可包括共稳定剂。例如，可以使用环氧化大豆油。还可以将润滑剂添加到耐磨层中，例如石蜡。任选地，还可以将UV稳定剂添加到耐磨层14中，耐磨层14包括UV吸收剂并阻碍胺以最大化UV稳定性的效率。
表1示出了根据本发明的耐磨层14的示例性组合物。
表格1：
打印层16可用于为地板镶板1提供打印图形，打印图形将用于增强地板镶板1的美感。在该实施例中，打印层16将是在打印层16的顶表面上具有打印设计的装饰层。打印层16的厚度可以在0.07-0.1mm的范围内。然而，在示例性实施例中，打印层16具有约0.07mm的优选厚度。尽管顶层10位于基部层20的顶部，但顶层10是透明的，允许容易看到基部层20的顶表面上的任何打印图案。
可以通过轮转凹版打印、柔版打印、数字打印或转印打印来打印打印层16。
在本发明的一个实施例中，打印层16的组合物包括聚氯乙烯和增塑剂。在本发明的一个实施例中，聚氯乙烯的K值在60-70的范围中。增塑剂优选为非邻苯二甲酸酯型增塑剂，如DOTP、DINCH和生物基增塑剂(即，十八烷酸、10-氯-9-甲氧基-甲酯等)。可以将稳定剂添加到打印层16的组合物中。优选使用非重金属含量型稳定剂，例如钙/硬脂酸盐和/或硬脂酸锌或钙/锌组合复合皂体系。打印层16还可包括共稳定剂。例如，可以使用环氧化大豆油。还可以将二氧化钛添加到打印层16中以增加不透明度。
表2示出了根据本发明的打印层16的示例性组合物。
表格2：
在制造期间，顶层10(单独的打印层16或薄涂层12、耐用耐磨层14和打印层16的组合)可以制备有纹理特征以增强地板镶板1的感觉。因此，如果顶层10制备有打印图案和纹理表面，则地板镶板1将具有真正的木材、陶瓷或变质岩石地板的外观和感觉。如果打印层16是地板镶板的最顶层，则打印层16应该由具有较高抗性和弹性的材料制备，而不是如果打印层16制备有顶部耐磨层10。
根据本发明，基部层20由多个聚氯乙烯层制备。在所示实施例中，基部层20包括上基部区段22、中间基部区段24、下基部区段26和玻璃纤维区段28。在示例性实施例中，上基部区段22、中间基部区段24、下基部区段26具有不同的聚氯乙烯和填料的组合物。
在所示实施例中，基部层20位于顶层10和背衬层30之间。基部层20是结构的主干，因为它主要影响机械性能，如产品的撕裂、凿孔、抗压痕、刚度、挠性等、以及成本、重量、尺寸稳定性、平整度和许多其他性能。基部层20结构中的层数取决于地板镶板1的总厚度(包括耐磨层14的厚度)、结构的平衡、每层的配方、以及产品成本等。
上基部区段22是打印层16正下方的层，包括聚氯乙烯和填料的组合物。可以提供其他组合物元素，包括增塑剂、稳定剂、颜料和阻燃剂。
上基部区段22具有比中间基部区段24和下基部区段26更多的每100份聚氯乙烯的填料量。结果，与中间基部区段24和下基部区段26相比，上基部区段22将具有更少的聚氯乙烯和增塑剂含量。在所示实施例中，上基部区段22提供地板的刚性和硬度。由于填料含量高且PVC和增塑剂的含量较少，因此该层的厚度对整个产品的成本具有极大的影响。
在所示实施例中，上基部区段22包括聚氯乙烯、主增塑剂、热稳定剂、共热稳定剂、填料、阻燃剂和颜料。增塑剂优选为非邻苯二甲酸酯型增塑剂，如DOTP、DINCH和生物基增塑剂(即，十八烷酸、10-氯-9-甲氧基-甲酯等)。上基部区段22还可包括稳定剂，例如非重金属含量型稳定剂。例如，非重金属含量型稳定剂可以是钙/硬脂酸盐和/或硬脂酸锌或钙/锌组合复合皂体系。上基部区段22还可包括共热稳定剂，例如环氧化大豆油。填料也可以加入上基部区段22中。例如，石灰石可以用作填料。可以使用阻燃剂，例如氢氧化镁。还可以加入颜料，例如炭黑或二氧化钛。
表3示出了根据本发明的上基部区段22的示例性组合物。
表格3：
成分 配方(phr)
PVC 100
增塑剂 25-35
热稳定剂 2.0-5.0
共稳定剂 4.0-6.0
填料 300-400
阻燃剂 10-20
颜料 0.3-1.0
在所示实施例中，上基部区段26包括两层材料，然后两层材料在制造期间与中间基部区段24和下基部区段26组合。然而，本领域技术人员应该理解，其他设计也是可能的，包括构成上基部区段22的单层的数量。
如图所示，中间基部区段24位于上基部区段22的下方。根据本发明，中间基部区段24具有与上基部区段22类似的组合物。然而，该组合物从高填料含量转变到低填料含量，且随后转变到较高的聚氯乙烯含量和增塑剂含量。结果，根据本发明的中间基部区段24在刚性、挠性、弹性和许多其他机械性能方面得到很好的平衡。
在所示实施例中，与上基部区段22类似，中间基部区段24包括聚氯乙烯、主增塑剂、热稳定剂、共热稳定剂、填料、阻燃剂和颜料。但是，组合物不同，如下表4所示。
在所示实施例中，中间基部区段24包括聚氯乙烯、主增塑剂、热稳定剂、共热稳定剂、填料、阻燃剂和颜料。增塑剂优选为非邻苯二甲酸酯型增塑剂，如DOTP、DINCH和生物基增塑剂(即，十八烷酸、10-氯-9-甲氧基-甲酯等)。中间基部区段24还可包括稳定剂，例如非重金属含量型稳定剂。例如，非重金属含量型稳定剂可以是钙/硬脂酸盐和/或硬脂酸锌或钙/锌组合复合皂体系。中间基部区段24还可包括共热稳定剂，例如环氧化大豆油。填料也可以加入中间基部区段24中。例如，石灰石可以用作填料。可以使用阻燃剂，例如氢氧化镁。还可以加入颜料，例如炭黑或二氧化钛。
表4示出了根据本发明的中间基部区段24的示例性组合物。
表格4：
成分 配方(phr)
PVC 100
增塑剂 28-40
热稳定剂 2.0-5.0
共稳定剂 4.0-6.0
填料 250-350
阻燃剂 10-20
颜料 0.3-1.0
在所示实施例中，中间基部区段24包括两个单独的材料层，然后两个单独的材料层在制造期间与上基部区段22和下基部区段26组合，这将在下面更详细地描述。然而，本领域技术人员应该理解，其他设计也是可能的，包括构成下基部区段26的单层的数量。
如图所示，下基部区段26位于中间基部区段24下方。根据本发明，下基部区段26具有与上基部区段22和中间基部区段24类似的组合物。然而，如前所述，基部层20的组合物从高填料含量转变为低填料含量。这是通过上基部区段22、中间基部区段24和下基部区段的层叠来进行的。随后，上基部区段26具有比上基部区段22、中间基部区段24更高的聚氯乙烯含量和增塑剂含量。
下基部区段26具有最多的聚氯乙烯和增塑剂。下基部区段中的聚氯乙烯和增塑剂的总含量取决于耐用耐磨层14的厚度。下基部区段26中的PVC和增塑剂含量较高，需要厚的耐用耐磨层14以获得结构的适当平衡，保持适当的平整度、尺寸稳定性。
在所示实施例中，与上基部区段22和中间基部区段24类似，下基部区段26包括聚氯乙烯、主增塑剂、热稳定剂、共热稳定剂、填料、阻燃剂、和颜料。但是，组合物不同，如下表5所示。
在所示实施例中，下基部区段26包括聚氯乙烯、主增塑剂、热稳定剂、共热稳定剂、填料、阻燃剂和颜料。增塑剂优选为非邻苯二甲酸酯型增塑剂，如DOTP、DINCH和生物基增塑剂(即，十八烷酸、10-氯-9-甲氧基-甲酯等)。下基部区段26还可包括稳定剂，例如非重金属含量型稳定剂。例如，非重金属含量型稳定剂可以是钙/硬脂酸盐和/或硬脂酸锌或钙/锌组合复合皂体系。下基部区段26还可包括共热稳定剂，例如环氧化大豆油。填料也可以加入下基部区段26中。例如，石灰石可以用作填料。可以使用阻燃剂，例如氢氧化镁。还可以加入颜料，例如炭黑或二氧化钛。
表5示出了根据本发明的下基部区段26的示例性组合物。
表格5：
成分 配方(phr)
PVC 100
增塑剂 35-55
热稳定剂 2.0-5.0
共稳定剂 4.0-6.0
填料 200-300
阻燃剂 10-20
颜料 0.3-1.0
在所示实施例中，下基部区段26包括单层材料，然后单层材料在制造期间与上基部区段22和中间基部区段24组合，这将在下面更详细地描述。然而，本领域技术人员应该理解，其他设计也是可能的，包括构成下基部区段26的多个层。如图4所示，下基部区段26可以被铣削或压印以在基部层20的底部形成图案。
根据本发明，基部层20包括玻璃纤维区段28，该玻璃纤维区段28被添加在基部区段内以提高刚性。在所示实施例中，玻璃纤维区段28位于上基部区段22和中间基部区段之间，以控制镶板1的膨胀和收缩。
在本发明的一个示例性实施例中，玻璃纤维区段28是一层玻璃纤维的纱，该层玻璃纤维的纱涂覆有聚乙烯基塑料溶胶，玻璃纤维的量在10g/m2至25g/m2的范围内。添加聚乙烯基塑料溶胶使得玻璃纤维区段28与基部层20的其他区段粘合。
基部层20的总厚度可以变化。然而，在所示的实施例中，制备厚度范围为2.8mm-4.7mm的基部层20。
如图3和4所示，背衬层30也是可选的，由单层防滑塑料制成。背衬层30用作防滑背衬层。另外，可以提供背衬层30以平衡顶层10，基本上避免地板镶板1的翘曲。尽管背衬层30的厚度可以变化，
但是提供厚度范围为0.2-1.0mm的背衬层30是合适的，在本发明的一个实施例中，背衬层30的厚度为0.2-0.3mm。背衬层30可以由多种材料制备，包括但不限于聚氯乙烯、聚丙烯、聚烯烃等。该组合物将取决于地板镶板1的预期应用。
在所示实施例中，背衬层30附接到下基部区段26并构成地板镶板1的底部，以便在安装地板镶板时使地板镶板1稳定而不移动。产生压印纹理图案以进一步增强其地板镶板1的防滑性能。可以压印背衬层30或者可以压印基部层20，然后在压印基部层上形成背衬层3020，如图所示。
在本发明的示例性实施例中，背衬层30具有聚氯乙烯和增塑剂的组合物。因此，背衬层30相当柔韧并且适合于底层地板的不规则性。
如图5-7所示，地板镶板包括榫槽式连接区段50、60。榫槽式连接区段50、60可以制成各种形状，即，尽管基本形状应包括一直沿地板镶板1的一侧切割的狭槽(槽连接区段60)，和在地板镶板的相反侧上的突起(榫舌连接区段50)。榫舌连接区段50与槽连接区段60几乎相同地突出，槽连接区段60被制备得较深。
榫舌连接区段50是在一侧上制备并且在长度上延伸超过地板镶板1的顶层10的突起。如图5中最佳所示，榫舌连接区段50具有第一引导元件52，第一引导元件52形成在榫舌连接区段50的下区段上。第一引导元件52是圆形的，其表面长度大于榫舌的顶表面53。因此，第一引导元件52延伸到相邻地板镶板1的主体中，如图7所示。顶表面53和榫舌端54应成形为具有平坦表面56和锥形表面58以在连接相邻的地板镶板时促进空气流动。
槽连接区段60形成在榫舌连接区段50的相对侧上。然而，槽连接区段60延伸超过地板镶板1的顶层10的周边边缘。第二引导元件62由凹部形成并具有向下凹的形状。第一引导元件52和第二引导元件62的尺寸在半径和长度上应该大致相同。槽连接区段60还包括上倾斜壁64和内壁66。
榫舌连接区段50和槽连接区段60形成为具有互补的形状，使得当榫舌连接区段50接合另一个地板镶板1的槽连接区段60时，顶表面53、榫舌端54和第一引导元件52分别抵靠上倾斜壁64、内壁66和第二引导元件62。由于引导元件52、62具有弯曲形状，因此连接地板镶板不能在水平方向上被拉开。
重要的是，榫舌连接区段50和槽连接区段60形成在基部层20中。在示例性实施例中，榫舌连接区段50由玻璃纤维区段28和中间基部区段24形成。然而，本领域技术人员应该理解，榫舌连接区段50可以形成在基部层20的其他区段中。
现在，将描述用于制造地板镶板1的示例性过程。
使用挤出过程和随后的四辊压延过程制备耐磨层14。根据每种配方的需要，耐磨层可包括聚乙烯粉末、增塑剂、稳定剂、共稳定剂、润滑剂和UV光稳定剂。将这些组分一起加入，然后在低剪切混合器中均匀混合。然后将混合物送入捏合挤出机，该捏合挤出机包括内置于混合室中的螺旋输送机。螺杆连续地远离排出端旋转并将材料移动到混合臂的范围内，然后从混合室中挤出以形成绳状挤出物。然后将挤出物送入到行星挤出机中。行星体系可以包括一个空心圆筒和一个主轴(螺钉)，以及几个卫星螺钉(主轴)，它们彼此和谐地同步，以实现令人满意的混合和塑化。然后通过较软的热熔阶段将挤出物材料进一步加工成熔体。然后通过压延辊磨机将熔体进行加工并加热至类似温度。压延辊的表面上的剪切混合作用使熔体熔化并形成具有受控厚度的聚合物片材。通过调节压延辊之间的距离来控制聚合物片材的厚度。然后根据下游操作的设备和过程将片材冷却并收集在卷轴上或切成片材。对于连续层压操作，片材以卷形式生成，然后切割成适合于热压机的尺寸的尺寸。
接下来，制备基部层20，其中上基部区段22、中间基部区段24和下基部区段26的每一层被单独制备。为简洁起见，仅描述上基部区段22的制备。然而，本领域技术人员将理解，可以利用具有不同组合物比的中间基部区段24和下基部区段26来执行相同的过程，如上所述。
首先，关于上基部区段22，将聚氯乙烯、稳定剂和颜料一起加入，然后使用剪切混合器均匀热混合。其余的组成元素，如填料和阻燃剂，进送入混合物中，然后送入捏合挤出机，石灰石均匀混入。然后将混合的组合物送入班伯里混合机，该混合机包括安装在混合室中以用于旋转的两个混合转子，以及安装用于使混合的化合物通过通道开口进入混合室中的滑块。然后经过一段时间当达到目标温度时，混合材料被排出。在此阶段，排出的材料在热熔形式处于150-215℃的温度。然后通过压延辊磨机将熔体进行加工并加热至类似温度。压延辊的表面上的剪切混合作用使熔体熔化并形成具有受控厚度的聚合物片材。通过调节压延辊之间的距离来控制上基部区段22的厚度。
然后将片材冷却并收集在卷轴上或切成片。
制造LVT的典型过程包括层压基部层20。在热和压力下压缩层压板。在本发明的一个实施例中，层压是连续层压。
在一个示例性实施例中，可以通过将下序列层压在一起来制备LVT：
(1)一层或多层下基部区段26；
(2)玻璃纤维区段28；
(3)一层或多层中间基部区段24；和
(4)一层或多层上基部区段22；
然后将基部层20的层压区段切割成板坯。例如，层压的基部层20可以切成1m×1m的板坯。
此时，可以铣削或压印下基部区段26以在基部层20的底部上形成图案。
制造LVT的典型过程包括热压基部层20和顶层10。在热和压力下压缩层压板。在本发明的一个实施例中，层压是连续层压。
在一个示例性实施例中，然后通过以下列顺序将层压基部层20与背衬层30和顶层10热压在一起来制备LVT：
(1)耐磨层14；
(2)打印层16；
(3)基部层20；和
(4)背衬层30。
将压印板放置在上述组装的叠层的顶部上。然后将叠层加热至约130℃-150℃，并在约20-30分钟内通过压印板施加约3-5MPa的压力。然后将压机冷却至30℃-50℃并除去LVT。
此外，然后将地板镶板1冷却几小时，然后在产品表面上施加紫外线固化涂料体系以形成薄涂层12。涂层材料通常用功能单体和光引发剂以及其它物质与聚氨酯丙烯酸酯低聚物一起配制，该其它物质在适当的UV能量下固化涂层并形成硬的三维交联表面。UV涂层为地板提供了优异的表面性能，如抗污性和耐化学性、外观和光泽保持性、耐刮擦性和耐磨性等。
涂覆后，通过退火进一步处理产品，以释放来自先前过程的内应力。如果没有适当的退火，产品的尺寸稳定性可能会受到影响。进一步的过程可以在退火之后进行，例如挤压、冲孔、成型，以形成榫槽式锁定轮廓，以及在包装成纸箱之前检查，以及工业中众所周知的过程。
前述内容说明了实践本发明的一些可能性。用于本发明的LVT的许多其他实施例和领域是可能的并且在本发明的范围和精神内。因此，意图是前面的描述被认为是说明性的而不是限制性的，并且本发明的范围由所附权利要求及其全部等同物给出。

Claims (29)

1.一种地板镶板的组合物，包括：
顶层；
基部层，所述基部层具有第一基部区段、第二基部和玻璃纤维区段，其特征在于：
第一基部区段包括聚氯乙烯、填料和增塑剂的第一组合物；
第二基部区段包括第二组合物，第二组合物具有比聚氯乙烯、填料和增塑剂的第一组合物更高含量的聚乙烯和增塑剂；并且
玻璃纤维区段位于第一基部区段和第二基部区段之间。
2.根据权利要求1所述的地板镶板，还包括，
突起，所述突起制备在所述基部层的一侧上并且向外延伸超出所述顶层。
3.根据权利要求2所述的地板镶板，其中，
所述第一基部区段的填料的量为300份/100份聚氯乙烯至400份/100份聚氯乙烯。
4.根据权利要求3所述的地板镶板，其中，
所述第一基部区段的增塑剂的量为25份/100份聚氯乙烯至35份/100份聚氯乙烯。
5.根据权利要求4所述的地板镶板，其中，
所述第一基部区段还包括热稳定剂，所述热稳定剂的量为2.0份/100份聚氯乙烯至5.0份/100份聚氯乙烯。
6.根据权利要求5所述的地板镶板，其中，
所述第一基部区段还包括共热稳定剂，所述共热稳定剂的量为4.0份/100份聚氯乙烯至6.0份/100份聚氯乙烯。
7.根据权利要求6所述的地板镶板，其中，
所述第一基部区段还包括阻燃剂，所述阻燃剂的量为10.0份/100份聚氯乙烯至20.0份/100份聚氯乙烯。
8.根据权利要求7所述的地板镶板，其中，
所述第一基部区段还包括颜料，所述颜料的量为0.3份/100份聚氯乙烯至1.0份/100份聚氯乙烯。
9.根据权利要求4所述的地板镶板，其中，
所述第二基部区段的填料的量为250份/100份聚氯乙烯至350份/100份聚氯乙烯。
10.根据权利要求9所述的地板镶板，其中，
所述第二基部区段的增塑剂的量为28份/100份聚氯乙烯至40份/100份聚氯乙烯。
11.根据权利要求10所述的地板镶板，其中，
所述第二基部区段还包括热稳定剂，所述热稳定剂的量为2.0份/100份聚氯乙烯至5.0份/100份聚氯乙烯。
12.根据权利要求11所述的地板镶板，其中，
所述第二基部区段还包括共热稳定剂，所述共热稳定剂的量为4.0份/100份聚氯乙烯至6.0份/100份聚氯乙烯。
13.根据权利要求12所述的地板镶板，其中，
所述第二基部区段还包括阻燃剂，所述阻燃剂的量为10.0份/100份聚氯乙烯至20.0份/100份聚氯乙烯。
14.根据权利要求13所述的地板镶板，其中，
所述第二基部区段还包括颜料，所述颜料的量为0.3份/100份聚氯乙烯至1.0份/100份聚氯乙烯。
15.根据权利要求10所述的地板镶板，还包括，
第三基部区段，所述第三基部区段沿所述第二基部区段定位，并且具有聚氯乙烯和填料，所述填料的量为200份/100份聚氯乙烯至300份/100份聚氯乙烯。
16.根据权利要求15所述的地板镶板，其中，
所述第三基部区段还包括增塑剂，所述增塑剂的量为35份/100份聚氯乙烯至55份/100份聚氯乙烯。
17.根据权利要求16所述的地板镶板，其中，
所述第三基部区段还包括热稳定剂，所述热稳定剂的量为2.0份/100份聚氯乙烯至5.0份/100份聚氯乙烯。
18.根据权利要求17所述的地板镶板，其中，
所述第三基部区段还包括共热稳定剂，所述共热稳定剂的量为4.0份/100份聚氯乙烯至6.0份/100份聚氯乙烯。
19.根据权利要求18所述的地板镶板，其中，
所述第三基部区段还包括阻燃剂，所述阻燃剂的量为10.0份/100份聚氯乙烯至20.0份/100份聚氯乙烯。
20.根据权利要求19所述的地板镶板，其中，
所述第三基部区段还包括颜料，所述颜料的量为0.3份/100份聚氯乙烯至1.0份/100份聚氯乙烯。
21.根据权利要求1所述的地板镶板，其中，
所述玻璃纤维区段是一层玻璃纤维的纱，所述一层玻璃纤维的纱涂覆有聚乙烯基塑料溶胶，所述玻璃纤维的量在10g/m2至25g/m2的范围内。
22.一种地板镶板的组合物，包括：
第一基部区段，所述第一基部区段具有第一聚合物、第一填料和第一增塑剂；
第二基部区段，所述第二基部区段具有第二聚合物、第二填料、第二增塑剂；
玻璃纤维区段；和
突起，所述突起由第二基部区段制备而成并从第一基部区段向外延伸；
其特征在于：
第一填料的量为300份/100份第一聚合物至400份/100份第一聚合物，且第一增塑剂的量为25份/100份第一聚合物至35份/100份第一聚合物；
第二填料的量为250份/100份第二聚合物至350份/100份第二聚合物，且第二增塑剂的量为28份/100份第二聚合物至40份/100份第二聚合物；并且
玻璃纤维区段位于第一基部区段和第二基部区段之间。
23.根据权利要求22所述的地板镶板，还包括，
第三基部区段，所述第三基部区段沿所述第二基部区段定位，并且具有聚氯乙烯和填料，所述填料的量为200份/100份聚氯乙烯至300份/100份聚氯乙烯。
24.根据权利要求23所述的地板镶板，其中，
所述第三基部区段还包括增塑剂，所述增塑剂的量为35份/100份聚氯乙烯至55份/100份聚氯乙烯。
25.根据权利要求24所述的地板镶板，其中，
所述第三基部区段还包括热稳定剂，所述热稳定剂的量为2.0份/100份聚氯乙烯至5.0份/100份聚氯乙烯。
26.根据权利要求25所述的地板镶板，其中，
所述第三基部区段还包括共热稳定剂，所述共热稳定剂的量为4.0份/100份聚氯乙烯至6.0份/100份聚氯乙烯。
27.根据权利要求26所述的地板镶板，其中，
所述第三基部区段还包括阻燃剂，所述阻燃剂的量为10.0份/100份聚氯乙烯至20.0份/100份聚氯乙烯。
28.根据权利要求27所述的地板镶板，其中，
所述第三基部区段还包括颜料，所述颜料的量为0.3份/100份聚氯乙烯至1.0份/100份聚氯乙烯。
29.根据权利要求22所述的地板镶板，其中，
所述玻璃纤维区段是一层玻璃纤维的纱，所述一层玻璃纤维的纱涂覆有聚乙烯基塑料溶胶，所述玻璃纤维的量在10g/m2至25g/m2的范围内。
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