CN114293732B - Composite floor and production process thereof - Google Patents
Composite floor and production process thereof Download PDFInfo
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- CN114293732B CN114293732B CN202111523344.7A CN202111523344A CN114293732B CN 114293732 B CN114293732 B CN 114293732B CN 202111523344 A CN202111523344 A CN 202111523344A CN 114293732 B CN114293732 B CN 114293732B
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Landscapes
- Floor Finish (AREA)
Abstract
The invention provides a composite floor and a production process thereof, wherein the floor comprises a support body made of metal materials and a buffer body which is clamped on the surface of the support body and mainly consists of polymer resin; the upper surface of the support body is provided with a clamping groove, and the buffer body extends towards the direction of the support body to form a clamping part matched with the clamping groove; the clamping groove is provided with a limiting part for preventing the clamping part from falling out of the clamping groove; the buffer body comprises a buffer body main body and a hard surface layer arranged on the surface of the buffer body main body; the clamping component is formed by a buffer body main body; the buffer body main body is made of foamed thermoplastic plastic, and the density is 0.8-1.2 g/cm; the hard surface layer is made of thermoplastic plastic, and the Shore hardness is more than 65 HD. The invention can greatly improve the bonding strength between the support body and the buffer body, and the bonding strength can not be obviously reduced when the factors such as temperature, humidity and the like are changed.
Description
Technical Field
The invention relates to the technical field of building floor decoration, in particular to a composite floor.
Background
The wood-plastic floor manufactured by taking plant fibers and thermoplastic plastics as main raw materials has the advantages of environmental protection, wood substitution, easy maintenance and the like, and more consumers select the wood-plastic floor to replace the traditional wood floor. The wood-plastic floor is generally prepared by mixing polyethylene and other hot-melt polymer materials with wood powder and auxiliary agents, and the prepared wood-plastic floor has the problems of low strength, easy bending deformation, flammability and the like due to the strength defect of the materials.
In order to solve the problems, some production schemes propose a floor structure which adopts aluminum alloy as a base material and wood-plastic material as a surface layer, wherein the floor structure utilizes the aluminum alloy base material to ensure the physical strength of the floor, improves the mechanical property and the bearing capacity of the floor, and simultaneously utilizes the wood-plastic material on the surface of the aluminum alloy base material to ensure that the floor has the characteristics of water resistance, wear resistance, elastic buffering effect of the surface layer and the like. An aluminum-plastic composite floor disclosed in the patent document with the patent application number of CN201410246694.7 is provided with an EVA hot melt adhesive layer, a PVC layer, a pattern layer and a wear-resistant layer on the upper surface of an aluminum alloy substrate. Although the hot melt adhesive is adopted in the patent to improve the bonding strength between the wood plastic and the aluminum alloy, the bonding strength depends on the bonding force between the hot melt adhesive and the aluminum alloy substrate layer, and the hot melt adhesive can gradually age to reduce the bonding effect along with the use of the floor, so that the service life of the floor is influenced to a certain extent.
Disclosure of Invention
In order to solve the above problems, the present invention provides a composite floor board, wherein a high-strength bonding force is provided between a metal substrate and a cladding material compounded on the surface of the substrate, so that the service life of the floor board is prolonged.
The invention adopts the following technical scheme:
A composite floor comprises a support body made of metal and a buffer body clamped on the surface of the support body and mainly composed of polymer resin; the upper surface of the support body is provided with a clamping groove, and the buffer body extends towards the direction of the support body to form a clamping part matched with the clamping groove; the clamping groove is provided with a limiting part for preventing the clamping part from falling out of the clamping groove; the buffer body comprises a buffer body main body and a hard surface layer arranged on the surface of the buffer body main body; the clamping component is formed by a buffer body main body; the buffer body main body is made of foamed thermoplastic plastic, and the density is 0.8-1.2 g/cm; the hard surface layer is made of thermoplastic plastic, and the Shore hardness is more than 65 HD.
In the prior art, the base material and the coating layer of the metal material are generally bonded in a mode of a base material plane-a coating layer plane, the bonding strength between the two planes is completely dependent on the compatibility of the materials between the base material and the coating layer, and the strength of the compatibility is mainly dependent on the physical adsorption strength of the polymer material forming the coating layer on the surface of the metal base material, the chemical bond strength formed by the polymer material and the metal atoms on the surface of the base material, and the like. The physical adsorption strength and the chemical bond strength are highly related to environmental factors, the physical adsorption strength and the chemical bond stability have larger fluctuation under different environmental conditions such as cold, heat, drying, humidity and the like, the floor can undergo multiple-round environmental changes in the long-term use process, and the bonding structure between the metal substrate and the coating layer is difficult to be ensured not to be damaged in the multiple-round environmental changes. And the peeling phenomenon easily occurs between the base material and the coating layer which are combined in a plane-plane mode, so that the service life of the floor is further influenced.
The buffer body is provided with the clamping groove, the clamping part is formed on the upper surface of the support body, the buffer body extends towards the direction of the support body, and when the clamping part is matched with the clamping groove, the limiting part arranged in the clamping groove can prevent the clamping part from falling out of the clamping groove, so that the buffer body and the support body form macroscopic physical clamping, and the buffer body and the support body can be continuously and stably compounded due to the fact that the physical clamping is basically not influenced by environmental factors. To separate the buffer body from the support body, the clamping component is required to be broken and separated from the buffer body, but the clamping component is integrally formed by the buffer body, so that the external force required by breaking and separating the clamping component is required to reach a higher level, the external force is far beyond the normal use range of the floor, and the floor can keep stable combination of the buffer body and the support body in the use process. In addition, the buffer body comprises two parts, a buffer body main body and a hard surface layer, wherein the buffer body main body is in clamping and combining with the support body, and the hard surface layer is formed on the surface of the buffer body main body. The buffer body main body is made of foaming materials, the foaming materials expand from extrusion to forming, the foaming materials are extruded to the surface of the support body in the floor production process, the foaming materials are filled in the clamping grooves, and the buffer body main body is different from the non-foaming materials in that the foaming materials expand to form tight fit with the groove walls of the clamping grooves after being filled in the clamping grooves, and the clamping parts and the clamping grooves are enabled to have stable clamping effects through pressure generated in the foaming process, so that the clamping parts are not easy to loosen in the clamping grooves. If the buffer body main body is made of a non-foaming material, the problem of incomplete filling easily occurs after the non-foaming material is filled into the clamping groove, and when air holes and cavities are reserved in the clamping groove, the clamping strength of the clamping part and the clamping groove is obviously reduced. Meanwhile, in the market, composite floors made of metal and polymer materials are accepted by consumers, and more beautiful and natural appearance is required in addition to durability, so that embossing lines are sometimes required to be formed on the surface of the floor to simulate wood grains or other pattern shapes. In addition, some applications require the floor to have a slip-resistant effect, and thus it is necessary to form a slip-resistant groove on the floor surface by embossing. For aluminum-plastic composite floors, embossing is achieved by processing a coating layer through an embossing roller, and in order to achieve a good embossing effect, a sufficient thickness of the coating layer is generally required to be ensured so as to ensure that clear patterns can be formed after the coating layer is processed by patterns on the embossing roller. The foam material has certain compressibility due to smaller density, and can form embossing lines more easily when being processed by the embossing roller, and the embossing lines are not easy to deform and disappear due to the rebound characteristic of the resin material. However, the foam material has the problems of insufficient surface physical properties and easy scratching and abrasion in addition to the advantages, so that the surface of the buffer body main body formed by the foam material is compounded with a hard surface layer formed by thermoplastic with the Shore hardness of more than 65HD so as to improve the surface physical properties of the floor.
Preferably, the material of the main body of the buffer body is hard foamed polyvinyl chloride, and the material of the hard surface layer is ASA. It should be noted that the "the material of the buffer body is hard foamed polyvinyl chloride" means that the main resin component in the composition of the buffer body is polyvinyl chloride, and a small amount of other resin materials with a content lower than that of polyvinyl chloride, or filling materials such as wood powder, and additives such as antioxidants and lubricants commonly used in the resin processing process may be added in addition to polyvinyl chloride, and the addition of the above materials is a common prior art in the field, so that the description is omitted. The material of the hard surface layer is ASA.
In order to further improve the bonding strength between the buffer body and the support body, the invention can also be provided with an adhesive layer between the support body and the buffer body. The adhesive layer may be a polymer material with self-adhesive property or a hot melt adhesive, and in order to facilitate coextrusion, it is generally preferable to use a hot melt adhesive. In the production process of the floor, hot melt adhesive is generally coated on the surface of a support body, and then a buffer body is coated on the basis of the hot melt adhesive. In the invention, the upper surface of the support body is provided with the clamping groove, so that the upper surface is divided into a plane part without the clamping groove and a groove part with the clamping groove, and in the hot melt adhesive coating process, the plane part and the groove part are preferably coated, namely the adhesive layer is provided with a flat adhesive part formed on the surface of the plane part and a groove adhesive part formed on the groove wall of the clamping groove. Preferably, the difference between the thickness of the flat glue part and the thickness of the groove glue part is not more than 0.2mm. The groove glue part formed in the clamping groove and the flat glue part formed in the plane part are integrally formed, the hot melt glue should form a groove glue part with uniform thickness and basically consistent with the flat glue part along the surface of the groove wall of the clamping groove, and the groove glue part is not naturally converged to form a structure with uneven thickness under the action of gravity at the groove bottom of the clamping groove.
Further, the supporting body comprises a connecting part clamped with the buffer body and a supporting part for supporting the connecting part; the connecting part is formed by integrally connecting a plurality of planar bodies and a plurality of groove-shaped bodies in a spacing mode; the supporting part is formed by integrally connecting a lamellar body arranged at the bottom and a plurality of lamellar bodies vertically arranged at the upper part of the lamellar body; the groove-shaped body comprises a middle groove-shaped body and an edge groove-shaped body, the middle groove-shaped body is arranged between two adjacent surface-shaped bodies, and the edge groove-shaped body is arranged on the outer side of the two surface-shaped bodies which are arranged outside the connecting part; the sheet-shaped bodies are supported and connected with the middle groove-shaped bodies in a one-to-one corresponding mode. Preferably, the middle groove body is horizontally arranged, and the edge groove body is inclined outwards.
The edge groove bodies refer to two groove bodies close to the edge parts of two sides of the support body, and the middle groove body refers to the rest groove bodies formed between the two edge groove bodies. The middle part of the floor plays a main structural supporting role, so that the flaky bodies arranged on the supporting parts are in one-to-one corresponding mode with the middle trough-shaped bodies for supporting and connecting, and the supporting parts have a uniform supporting effect on the connecting parts.
Under the general stress condition of the floor, the stress points of the supporting body are positioned at the surface-shaped body parts, then the pressure acts on the groove-shaped bodies connected to the two sides of the sheet-shaped body through the surface-shaped body, then the groove-shaped body acts on the sheet-shaped body, and finally the pressure is transferred to the lamellar body through the sheet-shaped body. When pressure acts on the groove-shaped body, the groove wall of the groove-shaped body is relatively vertically arranged, so that the compression resistance of the groove-shaped body is obviously higher than that of a plate structure horizontally arranged in the vertical direction, and therefore, the connection part between the connecting part and the supporting part is not easy to deform and break due to the pressure, and the groove-shaped body substantially plays a role similar to stamping reinforcing ribs. The bottom of the edge groove body is not connected with the sheet body, and only one side of the edge groove body is connected with the surface body, so that the structural mobility of the edge groove body is far higher than that of the middle groove body, namely the edge groove body is more easily elastically deformed under the action of pressure. When the floors are spliced with each other, when the side edge parts of two adjacent floors are mutually abutted, the edge groove-shaped bodies can be subjected to pressure in the horizontal direction so as to generate elastic deformation, so that the two adjacent floors are mutually extruded in the installation process of the floors, and the installation is more convenient. Preferably, the middle groove body is horizontally arranged, and the edge groove body is inclined outwards. In the case of the intermediate trough-like body, there are two trough-like parts located at the trough-like part for transitional connection with the planar body, and since both trough-like parts of the intermediate trough-like body are connected with the planar body, the line connecting the two trough-like parts should be horizontal on the premise that the plane of the planar body is horizontal, and thus the intermediate trough-like body is considered to be horizontally disposed. For the edge groove-shaped body, one groove-shaped part is connected with the surface-shaped body, and the other groove-shaped part is positioned below the surface-shaped body, so that when the two groove-shaped parts are connected, the connecting line is non-horizontal, and the opening of the middle groove-shaped body is vertically upwards, and the opening of the edge groove-shaped body is outwards and obliquely upwards in the whole structure.
Another object of the present invention is to provide a process for producing the above composite floor, comprising the steps of:
S1: preheating a support body made of metal, and conveying the support body to a processing flow passage of a die through a tractor;
s2: the support body reaches a first processing section of the processing flow channel, hot melt adhesive is extruded on the upper surface of the support body through a first extruder to form an adhesive layer, and a first coated substrate is obtained;
S3: the first cladding base material prepared in the step S2 reaches a second processing section of a processing flow channel, and a thermoplastic foaming material is extruded on the upper surface of the first cladding base material through a second extruder to form a buffer body main body, so that a second cladding base material is obtained;
S4: the second coating base material prepared in the step S3 reaches a third processing section of the processing flow channel, and thermoplastic plastics with the Shore hardness of more than 65HD are coated on the upper surface of the second coating base material through a third extruder to form a hard surface layer, so that a blank plate is obtained;
s5: the green plate prepared in the step S4 is transported out of the die, and the composite floor is obtained after shaping and embossing treatment;
the upper runner wall corresponding to the upper surface of the support body in the first processing section is provided with a plurality of protruding pieces, and each protruding piece corresponds to one clamping groove; when the support body reaches the first processing section, the protruding piece is embedded into the clamping groove, and a space is reserved between the outer contour of the protruding piece and the groove wall of the clamping groove to form an adhesive layer filling area.
The invention needs to make the foaming material enter the clamping groove and form the clamping component structure, however, in the process of coating the hot melt adhesive on the surface of the support body by adopting the conventional extrusion process, the hot melt adhesive can continuously flow into the clamping groove under the extrusion pressure, and the hot melt adhesive starts to be accumulated from the groove bottom part, so that the space in the clamping groove is gradually reduced and finally fills the clamping groove, and when the buffer body is coated in the second processing section, the foaming material forming the buffer body can not enter the clamping groove and finally the clamping component can not be formed. Therefore, after the convex parts are embedded into the clamping grooves, a space is reserved between the outer contours of the convex parts and the groove walls of the clamping grooves, and an adhesive layer filling area is formed, the adhesive layer filling area can only be filled with hot melt adhesive to form a groove adhesive part with uniform thickness, and after the first coating base material is led out of the first processing section, the convex parts are separated from the clamping grooves, and cavities for filling foaming materials are formed in the clamping grooves.
It is still another object of the present invention to provide a mold suitable for the above composite floor manufacturing process.
The mould for producing the composite floor comprises a plurality of mould blocks, wherein the mould blocks are assembled, and the middle parts of the mould blocks are all provided with through holes to form a complete processing flow passage; the processing flow channel is sequentially provided with a first processing section, a second processing section and a third processing section along the conveying direction of the substrate layer, a hot melt adhesive flow channel is arranged on a die block where the first processing section is positioned, and the hot melt adhesive flow channel is connected with a first extruder and is used for coating hot melt adhesive on the surface of the support body to form an adhesive layer; a foaming material runner is arranged on the die block where the second processing section is positioned, and the foaming material runner is connected with a second extruder and is used for coating foaming material on the surface of the support to form a buffer body main body; a surface layer runner is arranged on the die block where the third processing section is positioned, and the surface layer runner is connected with a third extruder and is used for coating hot melt plastic on the surface of the support body to form a hard surface layer; the calibers of the first processing section, the second processing section and the third processing section are sequentially increased so as to adapt to thickness variation in the floor covering process, and more particularly, the setting height of the upper wall of the through hole is sequentially increased while the setting height of the lower wall is unchanged; the upper wall of the through hole of the die block where the first processing section is located is provided with a plurality of protruding pieces, and the protruding pieces are arranged at positions corresponding to the positions of the clamping grooves of the supporting body one by one.
In the above technical solution of the present invention, the one-to-one correspondence between the positions of the protruding members and the positions of the clamping grooves of the supporting body means that when the supporting body is conveyed to the first processing section, the protruding members are embedded into the clamping grooves formed on the upper surface of the supporting body, and the external contour shape of the protruding members is consistent with the contour shape of the groove walls of the clamping grooves, and the difference is that the external contour shape of the protruding members is smaller than the contour shape of the groove walls, so that a certain interval area is formed between the protruding members and the groove walls of the clamping grooves, and the interval area is an adhesive layer filling area; through the restriction of protruding piece, when cladding the supporter upper surface, the hot melt adhesive can not fill up the joint groove, but only forms the even groove glue portion of thickness on the cell wall of joint groove.
In summary, the following beneficial effects can be obtained by applying the technical scheme of the invention:
1. In the invention, the clamping groove is formed on the upper surface of the support body, the buffer body is provided with the clamping part extending towards the direction of the support body, the buffer body and the support body can be firmly connected through the cooperation of the clamping groove and the clamping part, and the connection strength is basically not influenced by environmental factors such as temperature, humidity and the like.
2. According to the invention, the buffer body main body is made of the foaming material, the foaming material is extruded to the surface of the support body in the floor production process, and then the foaming material is filled in the clamping groove, unlike the non-foaming material, the foaming material can expand to form close fit with the groove wall of the clamping groove after being filled in the clamping groove, the formed clamping component and the clamping groove have stable clamping effect through the pressure generated in the foaming process, the clamping component is not easy to loosen in the clamping groove, and meanwhile, a layer of non-foaming hard plastic surface layer is arranged on the surface of the foaming support body main body, so that the problem of insufficient physical properties of the surface of the foaming material is solved.
3. In the invention, when the pressure applied to the floor acts on the groove-shaped body through the surface-shaped body, the groove wall of the groove-shaped body is relatively vertically arranged, so that the pressure resistance of the groove-shaped body is obviously higher than that of the horizontally arranged plate structure in the vertical direction, and the connection part between the connecting part and the supporting part is not easy to deform and break due to the pressure, and the groove-shaped body substantially plays a role similar to a stamping reinforcing rib.
4. The invention provides a special die for producing a composite floor, which is used for coating an adhesive layer on the surface of a support body, wherein a plurality of protruding parts are arranged on the upper groove wall of a first processing section, and each protruding part corresponds to one clamping groove; when the support body reaches the first processing section, the protruding piece is embedded into the clamping groove, a gap is reserved between the outer contour of the protruding piece and the groove wall of the clamping groove, an adhesive layer filling area is formed, when the adhesive layer is coated, the adhesive layer filling area can only be filled with hot melt adhesive, the clamping groove cannot be filled, and a buffer body for subsequent coating can smoothly form the clamping part.
Drawings
FIG. 1 is a schematic structural view and a partially enlarged view of a composite floor panel in example 1;
FIG. 2 is a schematic view of the structure of a support of the composite floor in example 1;
FIG. 3 is a schematic cross-sectional structure of the mold in example 2;
FIG. 4 is a schematic diagram and a partial enlarged view showing the matching structure of the substrate layer and the fourth mold block in example 2;
FIG. 5 is a schematic view of the structure of the support in comparative example 1;
In the figure, 1-supporting body, 2-buffer body, 3-adhesive layer, 4-mold, 11-connecting part, 12-supporting part, 21-buffer body main body, 22-hard surface layer, 31-flat glue part, 32-groove glue part, 41-first processing section, 41-second processing section, 43-third processing section, 101-clamping groove, 102-limiting part, 111-planar body, 112-groove body, 121-layer pile body, 122-sheet body, 211-clamping part, 411-protruding part and 412-adhesive layer filling area.
Detailed Description
The following description of the embodiments of the present invention will be made clearly and completely with reference to the accompanying drawings, in which it is apparent that the embodiments described are only some embodiments of the present invention, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
In the description of the present invention, it should be noted that, directions or positional relationships indicated by terms such as "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer", etc., are based on directions or positional relationships shown in the drawings, are merely for convenience of description and simplification of description, and do not indicate or imply that the apparatus or element to be referred to must have a specific direction, be constructed and operated in the specific direction, and thus should not be construed as limiting the present invention; unless specifically stated or limited otherwise, the terms "mounted," "connected," and "coupled" are to be construed broadly, and may be, for example, fixedly connected, detachably connected, or integrally connected; can be mechanically or electrically connected; can be directly connected or indirectly connected through an intermediate medium, and can be communication between two elements. The specific meaning of the above terms in the present invention will be understood in specific cases by those of ordinary skill in the art.
Example 1
As shown in fig. 1, the present embodiment provides a composite floor board, which includes a support body 1, a buffer body 2 composited on the upper surface of the support body 1, and an adhesive layer 3 disposed between the support body 1 and the buffer body 2.
Specifically, as shown in fig. 2, the support body 1 includes a connection portion 11 for forming a snap connection with the buffer body, and a support portion 12 disposed below the connection portion for supporting the connection portion. The supporting part consists of a layered body 121 which is horizontally arranged and a sheet-shaped body 122 which is longitudinally arranged, the lower end of the sheet-shaped body 122 is connected with the upper surface of the layered body, the upper end of the sheet-shaped body is connected with the lower surface of the connecting part, and a cavity is formed between two adjacent sheet-shaped bodies. The connection portion is formed by integrally connecting a plurality of planar bodies 111 and a plurality of groove bodies 112 at intervals, and all the planar bodies are on the same plane. The inside of the groove-shaped body is provided with a clamping groove 101, the notch part of the clamping groove is provided with a limiting part 102, and the clamping part 102 enables the notch part of the clamping groove to form a narrow opening relative to the inside of the clamping groove. Two groove-shaped bodies positioned on two sides of the supporting body are arranged in an outward inclined mode, and the groove-shaped bodies positioned in the middle are horizontally arranged. Each of the plate-like bodies 122 of the support portion is connected to the lower surface of one of the groove-like bodies 101 located in the middle, and the lower surfaces of the groove-like bodies located on both sides of the support body are not provided with the plate-like bodies 122.
As shown in fig. 1, the support body includes a cushioning portion main body 21 formed of a hard foam material and a hard skin layer 22 formed of a thermoplastic, and both sides of the adhesive layer 3 are bonded to the support body 1 and the cushioning portion main body 21, respectively. The buffer body extends in the direction of the support body 1 to form a clamping component 211 matched with the clamping groove 101, and after the clamping component is matched with the clamping groove, the limiting component 102 can prevent the clamping component from falling out of the clamping groove.
The adhesive layer 3 forms a coating layer with uniform thickness along the upper surface contour of the connecting portion 11, specifically, a planar flat adhesive portion 31 is formed on the surface adhesive layer of the planar body 111 of the connecting portion 11, a groove adhesive portion 32 with uniform thickness along the groove wall contour is formed in the clamping groove 101 of the groove-shaped body 112 of the connecting portion, and the thickness difference between the flat adhesive portion 31 and the groove adhesive portion 32 is smaller than 0.2mm.
Example 2
This example provides a production mold for the aluminum-plastic composite floor in example 1. As shown in fig. 3, the production mold 3 is assembled from a plurality of mold blocks, which are respectively named as a first mold block to a seventh mold block from left to right for convenience of description, and the substrate layer conveying direction is from the seventh mold block to the first mold block. The middle parts of the seven die blocks are respectively provided with a through hole, and the through holes of the seven die blocks form a complete processing flow passage. The processing flow path is provided with a first processing section 41, a second processing section 42 and a third processing section 43 in sequence along the conveying direction of the substrate layer, wherein the first processing section is formed by a through opening of a fourth die block, the second processing section is formed by a through opening of a third die block, and the third processing section is formed by the through openings of the first and second die blocks. A hot melt adhesive flow channel 41a is arranged on the fifth die block, and is connected with the first extruder and used for coating hot melt adhesive on the surface of the support body to form an adhesive layer; a foaming material runner 42a is arranged on the fourth die block, and is connected with the second extruder and used for coating foaming material on the surface of the support body to form a buffer body main body; the third die block is provided with a surface layer runner 43a which is connected with a third extruder and is used for coating the surface of the support body with hot melt plastic to form a hard surface layer. The hot melt adhesive runner and the processing runner are communicated at the joint of the fourth die block and the fifth die block, namely the hot melt adhesive runner extrudes the hot melt adhesive from the tail end of the fifth die block, the hot melt adhesive coats the upper surface of the support body in a through hole (namely the first processing section) of the fourth die block, the foaming material runner and the processing runner are communicated at the joint of the third die block and the fourth die block, and the surface layer runner and the processing runner are communicated at the joint of the second die block and the third die block. The first processing section, the second processing section and the third processing section are sequentially enlarged in caliber so as to adapt to thickness variation in the floor covering process, and more specifically, the setting height of the upper wall of the through hole is sequentially increased while the setting height of the lower wall is unchanged.
As shown in fig. 3 and fig. 4, the upper walls of the openings of the fourth die block and the fifth die block are provided with a plurality of protruding members 411, the protruding members extend from the start end of the fifth die block to the end of the fourth die block, the protruding members are arranged at positions corresponding to the positions of the clamping grooves 101 of the supporting body one by one, when the supporting body is conveyed to the fifth die block, the protruding members 411 are embedded into the clamping grooves 101 formed on the upper surface of the supporting body, the external contour shape of the protruding members is consistent with the contour shape of the groove walls of the clamping grooves 101, and the difference is that the external contour shape and size of the protruding members are smaller than the contour shape of the groove walls, so that a certain interval area is formed between the protruding members 411 and the groove walls of the clamping grooves 11, namely an adhesive layer filling area 412 is formed between the protruding members 411 and the groove walls of the clamping grooves 11, and when the supporting body is conveyed to the fourth die block, the first extruder extrudes hot melt adhesive on the upper surface of the supporting body through the hot melt adhesive flow channels 41a, and the adhesive layer filling area 412. Through the restriction of protruding piece, hot melt adhesive can not fill up the joint groove when cladding support body upper surface, but only forms the even groove glue portion of thickness on the cell wall in joint groove, and when the support body carried to second processing section (i.e. third mould piece), protruding piece separates from the joint groove, forms the cavity that supplies the foaming material to fill in the joint groove.
Example 3
This example provides a process for producing the aluminum-plastic composite floor of example 1 using the mold of example 2, comprising the steps of:
S1: preparing a support body made of aluminum alloy, the structure of which is shown in example 1; preheating a support body for 15s through a heating box at 130 ℃, and then conveying the support body into a processing flow channel of a die through a tractor; the mold structure is as in example 2;
S2: after the support body reaches a first processing section of the processing flow channel, extruding polyurethane hot melt adhesive on the upper surface of the support body through a first extruder to form an adhesive layer, so as to obtain a first coated substrate;
s3: the first coated substrate prepared in the step S2 reaches a second processing section of a processing flow channel, and polyvinyl chloride foaming material is extruded on the upper surface of the first coated substrate through a second extruder to obtain a second coated substrate;
S4: the second coating base material prepared in the step S3 reaches a third processing section of the processing flow channel, ASA plastic is coated on the upper surface of the second coating base material through a third extruder to form a hard surface layer, and a blank is obtained;
s5: the green plate prepared in the step S4 is transported out of the die, and the composite floor is obtained after shaping and embossing treatment;
Comparative example 1
The comparative example provides another aluminum-plastic composite floor production process, which specifically comprises the following steps:
S1: preparing a support body made of aluminum alloy, the structure of the support body is shown in fig. 5, and the difference between the support body and the embodiment 1 is that the support body is not provided with a clamping groove in the comparative example; preheating a support body for 15s through a heating box at 130 ℃, and then conveying the support body into a processing flow channel of a die through a tractor; the die construction was substantially the same as in example 2 except that no raised piece was provided on the upper wall of the port of the fourth die block;
S2: after the support body reaches a first processing section of the processing flow channel, extruding polyurethane hot melt adhesive on the upper surface of the support body through a first extruder to form an adhesive layer, so as to obtain a first coated substrate;
s3: the first coated substrate prepared in the step S2 reaches a second processing section of a processing flow channel, and polyvinyl chloride foaming material is extruded on the upper surface of the first coated substrate through a second extruder to obtain a second coated substrate;
S4: the second coating base material prepared in the step S3 reaches a third processing section of the processing flow channel, ASA plastic is coated on the upper surface of the second coating base material through a third extruder to form a hard surface layer, and a blank is obtained;
s5: the green plate prepared in the step S4 is transported out of the die, and the composite floor is obtained after shaping and embossing treatment;
Comparative example 2
The comparative example provides another aluminum-plastic composite floor production process, which specifically comprises the following steps:
S1: preparing a support body made of aluminum alloy, the structure of which is shown in example 1; preheating a support body for 15s through a heating box at 130 ℃, and then conveying the support body into a processing flow channel of a die through a tractor; the mold structure is as in example 2;
S2: after the support body reaches the first processing section of the processing flow channel, hot melt adhesive is not extruded, so that the support body is kept in an uncoated state;
s3: the support body reaches a second processing section of the processing flow channel, and polyvinyl chloride foaming material is extruded on the upper surface of the first cladding base material through a first extruder, so that the first cladding base material is obtained;
S4: the first coated substrate obtained in the step S3 reaches a third processing section of a processing flow passage, ASA plastic is coated on the upper surface of the first coated substrate through a second extruder to form a hard surface layer, and a blank is obtained;
s5: the green plate prepared in the step S4 is transported out of the die, and the composite floor is obtained after shaping and embossing treatment;
Comparative example 3
This comparative example provides another aluminum-plastic composite floor production process, the specific steps being substantially the same as example 3, except that when the first coated substrate reaches the second processing stage, a PVC non-foaming material containing no foaming agent is extruded to the surface of the first coated substrate through the second extruder.
The floors obtained in example 3 and comparative examples 1 to 3 were compared by experiments.
Glue strength experiment:
(1) According to the method of GB/T17657-2013, a steel clamp with the size of 20mm x 20mm is adhered to a sample by using an HY-914 quick adhesive, an adhesive layer is cut off along the outline of the steel clamp, after the steel clamp is firmly adhered, the steel clamp is pulled up by a tension meter along the direction perpendicular to the plane of a plate, or the steel clamp is placed downwards on the steel clamp to hang a heavy object and record the weight of the heavy object, and the maximum tension (N) or the maximum weight before delamination of a buffer body and an aluminum alloy support body is recorded and recorded as F, wherein the adhesive strength is P=F/S, and S is the area of the steel clamp. The results of the experiment are recorded in table 1, column a of bond strength.
(2) Placing the sample in a water bath environment at 60 ℃ for 12H, then placing the sample in an ultralow temperature refrigerator at-35 ℃ for 24H for freezing, forming a cycle, placing the sample in a normal temperature of 23+/-2 ℃ for 2H after five cycles, and drying; the samples were then tested according to method (1). The results of the experiment are recorded in table 1, column B of bond strength.
TABLE 1
As can be seen from Table 1, the four-layer aluminum-plastic composite floor prepared in the embodiment 3 of the invention has higher bonding strength, and the bonding strength is reduced slightly after being subjected to cold and hot cycle treatment at 60 ℃ and minus 35 ℃ and still maintains higher bonding strength. Comparative example 1 differs from example 3 only in that the support body was replaced, the upper surface of the support body in comparative example 1 was a flat, groove-free structure, and it can be seen from the data in table 1 that the bonding strength of comparative example 1 was greatly reduced, and the bonding strength was also greatly reduced after being subjected to the cold and hot treatment, as compared with example 3. Comparative example 2 is different from example 3 in that no adhesive layer was used, and the buffer body and the support body were directly compounded, and the bonding strength was also significantly reduced compared with example 3 from the experimental results, however, after the multi-cycle cold and heat treatment, it was found that the bonding strength was not greatly reduced. It can be seen from the combination of comparative examples 1 and 2 that the arrangement of the clamping grooves and the clamping members can greatly improve the problem that the bonding strength of the buffer body and the support body is easily affected by the environment, and avoid the problem that the bonding strength of the floor is greatly reduced after long-term use, so that the quality of the floor is problematic. Comparative example 3 differs from example 3 only in that the material of the cushion body is non-foamed polyvinyl chloride, and comparative example 3 has a higher bonding strength than comparative examples 1 and 2, but the bonding strength is smaller than example 3 because the clamping member formed by the cushion body made of the foamed material can be clamped with the clamping groove more stably.
The foregoing description is only of the preferred embodiments of the invention, and all changes and modifications that come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.
Claims (5)
1. A process for producing a composite floor, comprising the steps of:
s1: preheating a support body made of metal materials, and conveying the support body into a processing flow passage of a die through a tractor;
s2: the support body reaches a first processing section of the processing flow channel, hot melt adhesive is extruded on the upper surface of the support body through a first extruder to form an adhesive layer, and a first coated substrate is obtained;
S3: the first cladding base material prepared in the step S2 reaches a second processing section of a processing flow channel, and a thermoplastic foaming material is extruded on the upper surface of the first cladding base material through a second extruder to form a buffer body main body, so that a second cladding base material is obtained;
S4: the second coating base material prepared in the step S3 reaches a third processing section of the processing flow channel, and thermoplastic plastics with the Shore hardness of more than 65HD are coated on the upper surface of the second coating base material through a third extruder to form a hard surface layer, so that a blank plate is obtained;
s5: the green plate prepared in the step S4 is transported out of the die, and the composite floor is obtained after shaping and embossing treatment;
The composite floor comprises a support body made of metal materials and a buffer body clamped on the surface of the support body and mainly composed of polymer resin, wherein an adhesive layer is arranged between the support body and the buffer body, and the adhesive layer comprises a flat adhesive part and a groove adhesive part which are integrally connected; the upper surface of the support body is provided with a clamping groove, and the buffer body extends towards the direction of the support body to form a clamping part matched with the clamping groove; the clamping groove is provided with a limiting part for preventing the clamping part from falling out of the clamping groove; the buffer body comprises a buffer body main body and a hard surface layer arranged on the surface of the buffer body main body; the clamping component is formed by a buffer body main body; the buffer body main body is made of foamed thermoplastic plastic, and the density is 0.8-1.2 g/cm; the hard surface layer is made of thermoplastic plastic, and the Shore hardness is more than 65 HD; the thickness difference between the flat glue part and the groove glue part is not more than 0.2mm;
the upper runner wall corresponding to the upper surface of the support body in the first processing section is provided with a plurality of protruding pieces, and each protruding piece corresponds to one clamping groove; when the support body reaches the first processing section, the protruding piece is embedded into the clamping groove, and a space is reserved between the outer contour of the protruding piece and the groove wall of the clamping groove to form an adhesive layer filling area.
2. The process for producing a composite floor according to claim 1, wherein: the buffer body main body is made of rigid foamed polyvinyl chloride; the hard surface layer is made of ASA.
3. The process for producing a composite floor according to claim 1, wherein: the support body comprises a connecting part clamped with the buffer body and a support part for supporting the connecting part; the connecting part is formed by integrally connecting a plurality of planar bodies and a plurality of groove-shaped bodies in a spacing mode; the supporting part is formed by integrally connecting a lamellar body arranged at the bottom and a plurality of lamellar bodies vertically arranged at the upper part of the lamellar body; the groove-shaped body comprises a middle groove-shaped body and an edge groove-shaped body, the middle groove-shaped body is arranged between two adjacent surface-shaped bodies, and the edge groove-shaped body is arranged on the outer side of the two surface-shaped bodies which are arranged outside the connecting part; the sheet-shaped bodies are supported and connected with the middle groove-shaped bodies in a one-to-one corresponding mode.
4. A process for producing a composite floor according to claim 3, wherein: the middle groove-shaped bodies are horizontally arranged, and the edge groove-shaped bodies are obliquely arranged outwards.
5. The process for producing a composite floor according to claim 1, wherein: embossing lines are formed on the surface of the buffer body.
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