U.S. patent application number 17/254874 was filed with the patent office on 2021-11-25 for foamed floor with wood texture.
The applicant listed for this patent is ANHUI SENTAI WPC TEC FLOORING CO., LTD.. Invention is credited to Tangyong Dan, Donghui Huang, Daoyuan Tang.
Application Number | 20210363762 17/254874 |
Document ID | / |
Family ID | 1000005821123 |
Filed Date | 2021-11-25 |
United States Patent
Application |
20210363762 |
Kind Code |
A1 |
Huang; Donghui ; et
al. |
November 25, 2021 |
FOAMED FLOOR WITH WOOD TEXTURE
Abstract
The disclosure relates to a foamed floor with wood texture. It
belongs to the technical field of co-extruded foam plate. It
includes a foam matrix and a hard surface layer including (a) and
(b); (a): a first exposed surface, a connecting substrate and a
base layer formed by the first color resin; (b): a second exposed
surface and a connecting substrate formed by the second color
resin. The first exposed surface is composed of a plurality of
exposed units, and the second exposed surface is composed of a
plurality of sunken units. The exposed units and the sunken units
are arranged alternately. A connecting unit is arranged between the
adjacent exposed unit and the sunken unit, and it's composed of the
connecting substrate and a connecting profile. The disclosure uses
resin as a material, is based on two surface layers, and realizes
the realistic effect of wood texture through some levels of
expressions such as three-dimensional (depth of texture), color
difference, brightness etc. It can also realize a variety of wood
textures by adjusting the three-dimensional, chromatic aberration,
and brightness.
Inventors: |
Huang; Donghui; (Anhui
Province, CN) ; Tang; Daoyuan; (Anhui Province,
CN) ; Dan; Tangyong; (Anhui Province, CN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
ANHUI SENTAI WPC TEC FLOORING CO., LTD. |
Anhui Province |
|
CN |
|
|
Family ID: |
1000005821123 |
Appl. No.: |
17/254874 |
Filed: |
November 19, 2019 |
PCT Filed: |
November 19, 2019 |
PCT NO: |
PCT/CN2019/119345 |
371 Date: |
December 22, 2020 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B29L 2007/001 20130101;
B29C 48/49 20190201; B29C 48/07 20190201; B29C 48/0021 20190201;
B44F 9/02 20130101; B29C 48/17 20190201; E04F 15/107 20130101; B29C
48/002 20190201; B29C 48/0012 20190201; B29L 2007/002 20130101 |
International
Class: |
E04F 15/10 20060101
E04F015/10; B44F 9/02 20060101 B44F009/02; B29C 48/00 20060101
B29C048/00; B29C 48/07 20060101 B29C048/07; B29C 48/17 20060101
B29C048/17; B29C 48/49 20060101 B29C048/49 |
Foreign Application Data
Date |
Code |
Application Number |
Oct 24, 2019 |
CN |
2019110167583 |
Claims
1. A foamed floor with wood texture, comprising a foam matrix that
is formed of resin and has a block structure, and a hard surface
layer integrally connected with the foam matrix and covering at
least one surface thereof, the hard surface layer comprising a
first exposed surface that is formed by a first color resin and
substantially parallel to a surface of the foam matrix, and a
second exposed surface formed by a second color resin; a distance
from the second exposed surface to a surface covered by the foam
matrix being smaller than that from the first exposed surface to
the surface covered by the foam matrix; and the first exposed
surface being composed of a plurality of exposed units that are
roughly on a same plane; the second exposed surface being composed
of a plurality of sunken units, and the plurality of exposed units
being arranged alternately with the plurality of sunken units; the
hard surface layer also comprising a connecting unit between
adjacent exposed unit and sunken unit; the connecting unit
comprising a connecting substrate formed of the first color resin
and integrally connected to the first exposed surface, and a
connecting profile that is covering the connecting substrate and is
formed of the second color resin and integrally connected to the
second exposed surface; and, the hard surface layer also comprising
a base layer formed of the first color resin and integrally
connected to the connecting substrate and covered by the second
exposed surface; the first color resin and the first color resin
having two colors that are different.
2. The foamed floor with wood texture according to claim 1,
wherein: the foam matrix of the floor is made of PVC foamed
material, and the hard surface layer is made of ASA non-foamed
material.
3. The foamed floor with wood texture according to claim 1,
wherein: the first exposed surface has a thickness not less than
0.1 mm, and the second exposed surface has a thickness not less
than 0.05 mm.
4. The foamed floor with wood texture according to claim 1,
wherein: the foamed matrix of the floor is fed by a main extruder,
and the first exposed surface, the connecting substrate and the
base layer that are formed by the first color resin are fed by an
auxiliary extruder, and the second exposed surface and the
connecting profile that are formed by the second color resin are
fed by another auxiliary extruder.
5. A method for preparing a foamed floor with wood texture
according to claim 1, comprising the following steps: a, adding raw
materials and additives thereof that constitute a foam matrix to a
main extruder; melting and plasticizing the raw materials and
additives thereof in the main extruder, entering a main runner of a
mold, and being extruded from a die lip of the main runner; foaming
in a foaming cavity of the mold to form the foam matrix; b, adding
the raw materials and additives thereof that constitute a first
color resin to a first auxiliary extruder, and adding the raw
materials and additives thereof that constitute a second color
resin to a second auxiliary extruder; melting and plasticizing the
materials respectively in the first auxiliary extruder and the
second auxiliary extruder, respectively entering a first auxiliary
runner and a second auxiliary runner of the mold, and molten
materials flowing out from an I-shaped mouth of the first auxiliary
runner and an I-shaped mouth of the second auxiliary runner though
lateral diffusion of the first auxiliary runner and the second
auxiliary runner, so that the molten materials coat the foam matrix
in layers and extrudes from a die of the mold, to form a floor
precursor structure; the floor precursor structure having the foam
matrix, a first surface layer and a second surface layer, the
second surface layer being set between the first surface layer and
the foam matrix; c, cooling and shaping the floor precursor
structure; d, heating a surface of the floor precursor structure
after cooling and shaping to at least make the first surface layer
soft; e, embossing through an embossing roller, such that a part of
the first surface layer is pressed into a surface of the second
surface layer, making the first surface layer and the second
surface layer together show a prior state of the wood texture; f,
sanding to make the first surface layer that has not been pressed
into the surface of the second surface layer is worn, and a
corresponding part of worn area shows the second surface layer;
transforming the prior state of wood texture into wood texture.
6. The method for preparing a foamed floor with wood texture
according to claim 5, wherein: in step d, when heating a surface, a
temperature of the first surface layer is controlled to be within
250.degree. C.
7. The method for preparing a foamed floor with wood texture
according to claim 6, wherein: in step d, when heating a surface, a
tunnel oven is used for heating, and the temperature in the oven is
controlled at 150.about.250.degree. C., the time is controlled
within 3.about.20 s.
8. The method for preparing a foamed floor with wood texture
according to claim 6, wherein: in step e, when embossing through an
embossing roller, the embossing roller is a cold roller.
9. The method for preparing a foamed floor with wood texture
according to claim 6, wherein: in step f, when sanding, a sanding
machine is adopted.
Description
TECHNICAL FIELD
[0001] The disclosure relates to a foam floor, and more
particularly, but not exclusively, to a foamed floor with wood
texture. It belongs to the technical field of co-extruded foamed
plate.
BACKGROUND
[0002] Traditional wood-like floors are generally composite floors.
Each of them is composed of MDF substrate, wood grain decorative
paper, wear-resistant layer and balance layer at the bottom.
However, since the MDF substrate is prone to mold and rot, and
there is a fire risk, a floor with anti-mold and flame-retardant
functions is urgently needed in the field. In this case, PVC foam
floor has become a choice. However, the shape and appearance of the
PVC foam floor do not meet the traditional requirements of people
using it, resulting in its low added value and difficult to use in
a large area of the market.
[0003] The Chinese patent application with Publication No.:
CN102294812A discloses a polystyrene wood-like profile, which to a
certain extent solves the problem of appearance defects of the
plastic floor itself. The surface layer material and the core layer
material are put into the auxiliary extruder and the main extruder
respectively, and co-extruded into a mold, so that the surface
layer material is coated on the core layer material. The surface
layer material is high-impact polystyrene and contains flow
masterbatch with good compatibility with high-impact polystyrene
but different fluidity and dispersibility, and the core material is
polystyrene micro-foamed plate. The surface of the co-extruded
profile is embossed to produce a three-dimensional effect or other
effects.
Technical Problem
[0004] This method adopts color masterbatches of different
substrate colors to make base color masterbatches and flow texture
masterbatches respectively. The base color masterbatch has good
fluidity and may be dispersed in the base styrene material to form
a background color during processing. Flow texture masterbatch has
a low melt index and poor dispersibility, it cannot be uniformly
dispersed during processing and wood grain or other textures cannot
be formed with the extrusion of the material. The base color and
flow texture are prone to mutual fusion and cross-color in the
adjacent interfaces. The wood-like texture of the co-extruded floor
is quite different from the wood texture, and general users can
easily distinguish the above-mentioned floor from the solid wood
floor in appearance.
SUMMARY
[0005] To solve the above-mentioned problems, the present
disclosure provides a foamed co-extruded floor with the same
appearance as wood texture.
[0006] The technical solutions of the present disclosure to solve
the above problems are as follows:
[0007] a foamed floor with wood texture, including a foam matrix
that is formed of resin and has a block structure, and a hard
surface layer integrally connected with the foam matrix and
covering at least one surface thereof, the hard surface layer
including a first exposed surface that is substantially parallel to
one surface of the formed base and formed by the first color resin,
and a second exposed surface that is formed by the second color
resin; the distance from the second exposed surface to the surface
covered by the foam matrix being smaller than that from the second
exposed surface to the first exposed surface; and, the first
exposed surface being composed of a plurality of exposed units that
are substantially in the same plane, and the second exposed surface
being composed of a plurality of sunken units, the plurality of
exposed units and the plurality of sunken units being arranged
alternately; the hard surface layer also including a connecting
unit between the adjacent exposed unit and the sunken unit, the
connecting unit including a connecting substrate that is formed of
a first color resin and integrally connected with the first exposed
surface, and a connecting profile that is covering the connecting
substrate and formed of a second color resin and integrally
connected with the second exposed surface; and, the hard surface
layer also including a base layer that is formed of the first color
resin and integrally connected to the connecting substrate and
covered by the second exposed surface; the color of the first color
resin being different form that of the second color resin.
[0008] In the above technical solution of the present disclosure,
the hard surface layer not only plays a role of protecting and
restraining the foam matrix, but also the first exposed surface and
the second exposed surface of the hard surface layer are arranged
at intervals to form wood grain. Because the first exposed surface
and the second exposed surface are independent of each other and
connected integrally, and they have different colors, combined with
their different depths, a three-dimensional effect can be shown,
and different brightness levels under light can be also shown. So
the wood grain jointly expressed by the first exposed surface and
the second exposed surface has a realistic effect. The wood texture
formed based on this has multiple levels of expression, such as
color, three-dimension, brightness, and does not affect each other
at different levels of expression, and different objects of the
same level of expression do not affect each other, not only the
wood texture effect is realistic, a variety of wood textures can be
also shown by adjusting multiple levels to better meet the needs of
the market. The first exposed surface and the second exposed
surface are independent of each other because there are layers
between them; the integral connection is achieved since their
interlayer connection is not realized by means such as glue.
[0009] In embodiments, the foam matrix of the floor may be made of
PVC foam material, and the hard surface layer may be made of ASA
non-foam material.
[0010] In an example, the thickness of the first exposed surface
may be not less than 0.1 mm, and the thickness of the second
exposed surface may be not less than 0.05 mm.
[0011] In an example, the density of the foamed floor with wood
texture may be 0.6-1.0 g/cm.sup.3, and the surface hardness may be
60-90 Rockwell.
[0012] In an example, the foam matrix of the floor may be fed by
the main extruder, and the first exposed surface formed by the
first color resin, the connecting substrate and the base layer may
be fed by an auxiliary extruder, the second exposed surface formed
by the second color resin and the connecting profile may be fed by
another auxiliary extruder.
[0013] Another object of the present disclosure is to provide a
method for preparing the above-mentioned foamed floor with wood
texture.
[0014] The method includes the following steps:
[0015] a, adding the raw materials and additives that constitute
the foam matrix to the main extruder; the raw materials and their
additives being melted and plasticized in the main extruder,
entering the main runner of the mold, and being extruded from the
die lip of the main runner, entering the foam cavity of the mold to
form, then to form a foam matrix;
[0016] b, adding the raw materials and additives that constitute
the first color resin to the first auxiliary extruder, and adding
the raw materials and additives that constitute the second color
resin to the second auxiliary extruder; melting and plasticizing
the materials respectively in the first auxiliary extruder and the
second auxiliary extruder, the materials respectively entering the
first auxiliary runner and the second auxiliary runner of the mold,
and the molten materials flowing out from the I-shaped mouth of the
first auxiliary runner and the I-shaped mouth of the second
auxiliary runner respectively through the lateral diffusion of the
first auxiliary runner and the second auxiliary runner, so that the
molten materials coat the foam matrix in layers, and are
co-extruded from the die of the mold to form the floor precursor
structure; The floor precursor structure has a foam matrix, a first
surface layer and a second surface layer, and the second surface
layer may be arranged between the first surface layer and the foam
matrix;
[0017] c, cooling and molding the floor precursor structure;
[0018] d, heating the surface of the floor precursor structure
after cooling and molding to at least soften the first surface
layer;
[0019] e, pressing a part of the first surface layer below the
surface of the second surface layer through the embossing process
of the embossing roller, so that the first surface layer and the
second surface layer together show the prior state of the wood
texture;
[0020] f, sanding, so that the first surface layer that has not
been pressed into the surface of the second surface layer may be
worn out, and the corresponding part of the worn area presents the
second surface layer; transforming the prior state of the wood
texture into the wood texture.
[0021] In an example, in step d, when heating the surface, the
temperature of the first surface layer may be controlled within
250.degree. C.
[0022] In an example, in step d, when heating the surface, a tunnel
oven may be adopted for heating, the temperature in the oven may be
controlled at 150-250.degree. C., and the time may be controlled at
3-20 s.
[0023] In an example, in step e, during embossing process of the
embossing roller, the embossing roller may be a cold roller.
[0024] In an example, in step f, when sanding, a sanding machine
may be used.
[0025] The present disclosure adopts the layered co-extrusion
method to co-extrude the surfaces of the two layers on the foam
layer, and to press the surfaces of the two layers through the
embossing roller to extrude the prior state of the wood texture;
after process of the embossing roller, the floor surface forms some
areas with different shades, the first surface layer of some areas
is embossed below the second surface layer. The first surface layer
can be removed by sanding, and the part of the first surface layer
that is embossed below the second surface layer cannot be removed,
so the second surface layer remains the second surface layer and
part of the first surface layer together to form a wood texture,
which has a realistic effect.
Beneficial Effect
[0026] In sum, the present disclosure has the following beneficial
effects:
[0027] The foamed floor with wood texture of the present disclosure
uses resin as a material, based on two surface layers and through
multiple levels of expressions, such as three-dimensional (depth of
texture), chromatic aberration, and brightness, to realize the
lifelike effect of wood texture. And it can also realize a variety
of wood textures by adjusting the three-dimensional, chromatic
aberration, and brightness.
DESCRIPTION OF THE DRAWINGS
[0028] FIG. 1 is a schematic diagram showing the floor precursor
structure of the present disclosure;
[0029] FIG. 2 is a schematic diagram showing the co-extruded floor
of the present disclosure;
[0030] FIG. 3 is a partial enlarged view of FIG. 2;
[0031] FIG. 4 is a schematic diagram showing the structure of the
mold of the present disclosure;
[0032] FIG. 5 is a front view of the Plate A in FIG. 4;
[0033] FIG. 6 is a front view of Plate B in FIG. 4;
[0034] FIG. 7 is a front view of the Plate C in FIG. 4;
[0035] In the figure, 1--first surface layer module, 2--second
surface layer module, 3--main runner module; 4--baffle plate,
5--mold outlet; 10--first surface layer casting cavity, 20--second
surface layer casting cavity; 21--the second surface layer feeding
plate, 22--second surface layer forming plate; 100--first surface
layer runner, 200--second surface layer runner; 101--material inlet
of the first surface layer module; 201--material inlet of the
second surface layer module; 202--material outlet of the second
surface layer feeding plate; 203--material inlet of the second
surface layer forming plate; 1000--foam matrix, 2000--hard surface
layer, 2001--first exposed surface, 2002--second exposed surface,
2003--base layer, 2010--connecting substrate, 2020--connecting
profile; 2001'--first surface layer, 2002'--second surface
layer.
Embodiments
[0036] As shown in FIG. 2, a foamed floor with wood texture may
include a foam matrix 1000 and a hard surface layer 2000. The hard
surface layer 2000 may be a three-dimensional concave-convex
structure where the convex surface may be a first exposed surface
2001, and the concave surface may be a second exposed surface 2002.
The first exposed surface 2001 may be formed of a first color resin
and may be substantially parallel to one surface of the foam matrix
1000. The second exposed surface 2002 may be formed of a second
color resin. A certain color difference may be formed between the
first color resin and the second color resin.
[0037] The first exposed surface 2001 may be composed of a
plurality of exposed units substantially on the same plane, and the
second exposed surface 2002 may be composed of a plurality of
sunken units. The exposed units and the sunken units may be
arranged alternately.
[0038] As shown in FIG. 3, a connecting unit may be provided
between the adjacent exposed unit and the sunken unit, which may be
a part of the hard surface layer 2000. The connecting unit may
include a connecting substrate 2010 and a connecting profile 2020
that may be integrally connected. The connecting substrate 2010 may
be formed of the first color resin and may be integrally connected
with the first exposed surface; the connecting profile 2020 may
cover the connecting substrate 2010 and may be formed of the second
color resin.
[0039] The hard surface layer 2000 may further include a base layer
2003 that may be formed of the first color resin and may be
integrally connected with the connecting substrate 2010, and
covered by the second exposed surface 2002.
[0040] In the foamed floor with wood texture of this embodiment,
the foam matrix 1000 may be made of PVC micro-foamed material, and
the hard surface layer 2000 may be made of ASA. The thickness of
the first exposed surface 2001 may be 0.2 mm, and the thickness of
the second exposed surface 2002 may be 0.08 mm. The density may be
0.72 g/cm.sup.3, and the surface hardness may be 72 Rockwell. The
manufacturing method of the above-mentioned foamed floor with wood
texture may include the following steps:
[0041] a, adding the raw materials and additives that make up the
foam matrix 1000 to the main extruder after mixing by a high-speed
mixer; melting and plasticizing the raw materials and their
additives in the main extruder and entering the main runner of the
mold; extruding from the die lip of the main runner and entering
the foaming cavity of the die to foam to form the foam matrix
1000;
[0042] b, adding the raw materials and additives that constitute
the first color resin, and the raw materials and the additives that
constitute the second color resin to the first auxiliary extruder
and the second auxiliary extruder respectively after mixing by a
high-speed mixer; melting and plasticizing the materials in the
first auxiliary extruder and the second auxiliary extruder,
respectively, then entering the first surface runner and the second
surface runner of the mold; the molten material flowing out from
the I-shaped mouths of the first surface runner and the second
surface runner, respectively though through lateral diffusion of
the first surface runner and the second surface runner, and
entering the first surface casting cavity and the second surface
casting cavity; the molten material coating the foam matrix 1000 in
layers, and co-extruding from the die of the mold; air-cooling and
shaping in the shaping mold after extrusion, and forming the floor
precursor structure after shaping; As shown in FIG. 1, the floor
precursor structure may have a foam layer 1000, a first surface
layer 2001' and a second surface layer 2002';
[0043] c, water cooling and shaping the floor precursor
structure;
[0044] d, heating the surface of the floor precursor structure
after water cooling and shaping to make the first surface layer
2001' and the second surface layer 2002' soften; Specifically,
through a tunnel heating oven, the temperature of the oven may be
controlled at 200.degree. C., with 10 s of the time of the tunnel
heating oven, the first surface layer 2001' may be heated to about
90.degree. C. to soften it and be suitable for embossing
texture;
[0045] e, embossing though the embossing roller, to make a part of
the first surface layer 2001' pressed below the surface of the
second surface layer 2002', so that the first surface layer 2001'
and the second surface layer 2002' together show the prior state of
the wood texture;
[0046] f. sanding, so that the first surface layer 2001' that has
not been pressed into the surface of the second surface layer 2002'
may be worn out, and the corresponding part of the worn area
presents the second surface layer 2002'; transforming the prior
state of the wood texture into the wood texture.
[0047] In the above-mentioned technical solution of the embodiment,
the raw materials and additives that constitute the foam matrix
1000, and the raw materials and the additives that constitute the
hard surface layer 2000 belong to the prior art, so detailed
descriptions may be omitted.
[0048] As shown in FIG. 4, a mold for manufacturing the
above-mentioned foamed floor may include a main runner module 3, a
second surface layer module 2 and a first surface layer module 1,
consisting of eight runner plates A-H.
[0049] Among them, the plates D-H may be provided with the main
runner 300 of the core layer of the mold, which may be used to form
the core foam layer of the foamed co-extruded floor with wood-like
texture.
[0050] Also referring to FIG. 7, in addition to the main runner 300
of the mold core layer, the plate C may be also provided with a
material inlet 201 of the second surface layer module and the
material outlet 202 of the second surface layer feeding plate. The
inlet and the outlet may be connected by a runner.
[0051] Also referring to FIG. 6, in addition to the main runner 300
of the mold core layer, the plate B may be also provided with a
material inlet 203 of the second surface layer forming plate and a
second surface layer runner 200. A second surface layer casting
cavity 20 may be formed between the second surface layer runner 200
and the main runner 300. Baffle plates 4 may be also provided at
both ends of the second surface layer casting cavity 20. The second
surface layer runner 200 may be connected with the second surface
layer casting cavity 20 through an I-shaped mouth. This arrangement
can make the melt of the second surface layer covered on the core
layer plate in a semi-covered manner to form the first
intermediate.
[0052] The plate C may be the second surface layer feeding plate
21, and the plate B may be the second surface layer forming plate
22. The material outlet 202 of the second surface layer feeding
plate may be connected to the material inlet 203 of the second
surface layer forming plate. The second surface layer casting
cavity 20 may be arranged on the second surface layer forming plate
22, and the material inlet 201 of the second surface layer module
may be arranged on the side of the entire mold.
[0053] The plate B and the plate C together constitute the second
surface layer module 2.
[0054] Also referring to FIG. 5, in addition to the main runner 300
of the mold core layer, the plate A may be also provided with a
material inlet 101 of the first surface layer module and the first
surface layer runner 100. A first surface casting cavity 10 may be
formed between the first surface layer runner 100 and the main
runner 300. Baffle plates 4 may be also provided at both ends of
the first surface layer casting cavity 10. The first surface layer
runner 100 and the first surface layer casting cavity 10 may be
communicated with each other through an I-shaped mouth. This
arrangement can make the melt of the first surface layer covered on
the first intermediate in a semi-covered manner to form the
precursor structure of the foamed floor with wood texture.
[0055] In this embodiment, the first surface layer module 1 may be
solely composed of a runner plate, that is, the plate A. The
material inlet 101 and the mold outlet 5 of the first surface layer
module may be both arranged on the plate A, while the material
inlet 101 of the first surface layer module may be arranged on the
upper part of the mold.
[0056] In order to prevent cross-color between the first surface
layer and the second surface layer, the distance between the
material outlet of the first surface layer casting cavity 10 and
the material outlet of the second surface layer casting cavity 20
in the die ejection direction may be not less than 0.1 mm.
[0057] After subsequent processing, the precursor structure of the
foamed floor with wood texture can obtain the foamed floor with
wood texture. The post-processing may be based on two surface
layers. The Chinese disclosure application with publication No.
CN102294812A has only one surface layer, so it may be relatively
monotonous in terms of expression. For floors based on two surface
layers, two surface layers can be processed separately, such as
using different colors for the two surface layers, embossing the
upper surface layer, and removing part of the surface layer after
embossing to make the floor surface appear two levels of surface,
from the perspective of three-dimensional (embossing depth),
chromatic aberration, brightness, etc., a realistic effect of
texture would be achieved.
* * * * *