CN104746837B - 混合地板产品 - Google Patents
混合地板产品 Download PDFInfo
- Publication number
- CN104746837B CN104746837B CN201410805248.5A CN201410805248A CN104746837B CN 104746837 B CN104746837 B CN 104746837B CN 201410805248 A CN201410805248 A CN 201410805248A CN 104746837 B CN104746837 B CN 104746837B
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- China
- Prior art keywords
- weight
- floor system
- base material
- sandwich layer
- filler
- 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.)
- Expired - Fee Related
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Abstract
本发明公开了地板***,其包含垫层和包含芯层的基材,所述芯层包含粘合剂和填料;其中所述粘合剂和填料按比重比例提供。还描述了制造和使用所述地板***的方法。
Description
相关申请的交叉引用
本申请要求2013年12月31日提交的美国临时专利申请序列号61/922,650的优先权的权益,其内容特此以引用的方式并入本文。
背景技术
实芯硬木地板***以其质量而闻名,因为富含硬木可以为任何房间增添非凡的魅力。虽然出于美观而可取,但是硬木地板受环境条件影响。因此,需要考虑环境温度的变化。
近年来,已经研发了使用木塑复合物(WPC)的替代性地板***来代替地板***中的天然木材。WPC变得越来越受欢迎,因为这些替代性地板***可改善与实木地板相关的湿度相关尺寸稳定性问题。然而,已知的WPC具有源于温度相关尺寸稳定性的限制。
因此,需要在各种温度和湿度条件下表现出更高尺寸稳定性的WPC产品。本发明的实施方案针对这些和其他目的。
发明内容
本发明的实施方案提供了一种地板***,其包括:基材和垫层,其中所述基材包括芯层,所述芯层包括粘合剂和填料;其中所述粘合剂和填料按约1:1至约1:3的重量比存在。
其他实施方案提供了一种地板组合物,其包括:乙烯基表面;芯层;和软木垫层;其中所述芯层包括含聚合物组分的粘合剂,聚合物组分至少具有包括PVC的第一聚合物和包括均聚物、共聚物、共混聚合物或其组合的第二聚合物。
还有其他实施方案提供了提高WPC地板***的热稳定性的方法,包括制备包括粘合剂和填料的芯层;其中所述粘合剂和填料按约1:1至约1:3的重量比提供。
具体实施方式
在一些实施方案中,本发明提供了一种具有包括基材和垫层的多层的地板***。在一些实施方案中,基材和垫层各自具有上表面和下表面。在一些实施方案中,垫层的下表面位于底层地板附近,并且垫层的上表面位于基材的下表面附近。一些实施方案提供了在安装地板***后,将位于基材和底层地板之间的垫层。
在一些实施方案中,基材包括含粘合剂和填料的芯层。在一些实施方案中,粘合剂和填料按范围从约1:1至约1:4的重量比存在。在一些实施方案中,粘合剂和填料按约1:1至约1:3的重量比存在。在一些实施方案中,粘合剂和填料按约1:1至约1:2的重量比存在。
在一些实施方案中,所述芯层包括约20重量%至约40重量%的粘合剂。在一些实施方案中,所述芯层包括约25重量%至约35重量%的粘合剂。在一些实施方案中,所述芯层包括约32重量%的粘合剂。
在一些实施方案中,粘合剂包括在自然界中为无定形或结晶或半结晶的聚合物。如本文所使用,可如Fox在Bull.Amer.Physics.Soc.,1,3,第123页(1956)中所述,计算任何聚合物的“玻璃态转化温度”或Tg。实验上,也可使用差示扫描量热法测量Tg(加热速率20℃/min,在拐折或峰值中点取Tg)。除非另外说明,如本文所使用的规定Tg指计算Tg。在一些实施方案中,聚合物组分的Tg介于90℉和约150℉之间,可选地100℉和约150℉之间,可选地90℉和约140℉之间。在一些实施方案中,粘合剂的Tg介于90℉和约150℉之间,可选地100℉和约150℉之间,可选地90℉和约140℉之间。
在一些实施方案中,聚合物组分包括均聚物、共聚物、三元共聚物、共混聚合物或其中两种或更多种的组合。在一些实施方案中,聚合物组分包括乙烯聚合物、聚烯烃、芳香族或脂肪族聚酯、丙烯酸聚合物、无机聚合物或其中两种或更多种的组合。具体地,聚合物可包括氯乙烯均聚物(例如PVC)、氯乙烯共聚物或三元共聚物、丙烯腈-丁二烯-苯乙烯、聚丙烯、聚乙烯、聚对苯二甲酸乙二醇酯、聚对苯二甲酸丙二酯、聚对苯二甲酸丁二酯、丙烯酸酯或丙烯酸聚合物、聚硅氧烷(例如聚二甲基硅氧烷)、铂催化的硅酮或其中两种或更多种的组合。
氯乙烯共聚物或三元共聚物可包括嵌段共聚物、三元共聚物等,并且包括卤化乙烯共聚用单体例如溴化乙烯和氟化乙烯;乙烯酯例如醋酸乙烯酯、氯代醋酸乙烯酯、丁酸乙烯酯、其他脂肪酸乙烯酯、烷基磺酸乙烯酯等;乙烯基醚例如乙烯基***、乙烯基异丙醚、乙烯基氯***等;环状不饱和化合物例如苯乙烯、单或聚氯苯乙烯、香豆酮(coumarone)、茚、乙烯基萘、乙烯基吡啶、乙烯基吡咯等;丙烯酸及其衍生物例如丙烯酸乙酯、甲基丙烯酸甲酯、甲基丙烯酸乙酯、氯丙烯酸乙酯、丙烯腈、甲基丙烯腈、马来酸二乙酯、富马酸二乙酯等;亚乙烯基化合物,例如双氯亚乙烯、双溴亚乙烯、氟氯亚乙烯等;不饱和烃例如乙烯、丙烯、异丁烯等;烯丙基化合物,例如醋酸烯丙酯、烯丙基氯、烯丙基***等;或共轭或交叉共轭烯属不饱和化合物例如丁二烯、异戊二烯、氯丁二烯、2,3-二甲基丁二烯-1,3-戊间二稀、二乙烯基酮等。
所述聚合物也可为生物基聚合物(例如亚麻籽油)或聚酯,如基于1,3-丙二醇、1,4-丁二醇、甘油、癸二酸、琥珀酸、己二酸、壬二酸、柠檬酸和对苯二甲酸。在一些实施方案中,生物基聚合物可与其它聚合物组合。
在一些实施方案中,芯层可包括约10重量%至约40重量%的聚合物组分。在一些实施方案中,芯层可包括约15重量%至约35重量%的聚合物组分。在一些实施方案中,芯层可包括约20重量%至约25重量%的聚合物组分。在一些实施方案中,芯层可包括约23重量%的聚合物组分。
在一些实施方案中,聚合物组分进一步包括热固性材料。在一些实施方案中,芯层可包括约0.01重量%至约15重量%的热固性材料。在一些实施方案中,热固性材料选自聚氨酯、聚乙烯、聚苯乙烯和天然或合成橡胶。在一些实施方案中,热固性材料为芯层增加强度和/或加工性。
在一些实施方案中,聚合物组分包括PVC和本文所述另一种聚合物的共混物。在一些实施方案中,PVC和第二聚合物按约1:10至约10:1,可选地约1:9至约9:1,可选地约1:8至约8:1,可选地约1:7至约7:1,可选地约1:6至约6:1,可选地约1:5至约5:1,可选地约1:4至约4:1,可选地约1:3至约3:1,可选地约1:2至约2:1,和可选地约1:1的重量比存在。
在一些实施方案中,粘合剂进一步包括增塑剂。在一些实施方案中,增塑剂为羧酸酯,例如邻苯二甲酸烷基苄酯、邻苯二甲酸二烷基酯、苯甲酸烷基酯等。在一些实施方案中,增塑剂选自邻苯二甲酸丁苯酯、邻苯二甲酸二异壬酯、对苯二甲酸二辛酯、邻苯二甲酸二丁酯、邻苯二甲酸二丁氧基乙酯、邻苯二甲酸丁辛酯、邻苯二甲酸二己酯、邻苯二甲酸二辛酯、邻苯二甲酸二异辛酯、邻苯二甲酸二仲辛酯、邻苯二甲酸二仲辛二正辛酯、邻苯二甲酸二异癸酯、邻苯二甲酸十三烷基酯、二异壬基环己烷、苯甲酸酯及其中两种或更多种的组合。
在一些实施方案中,芯层包括约0.01重量%至约15重量%的增塑剂。在一些实施方案中,芯层包括约0.1重量%至约12重量%的增塑剂。在一些实施方案中,芯层包括约1重量%至约10重量%的增塑剂。在一些实施方案中,芯层包括约8.5重量%的增塑剂。在一些实施方案中,芯层包括约8重量%的增塑剂。
在本发明的一些实施方案中,芯层包括填料。在一些实施方案中,填料包括选自石灰石、粘土、滑石、木质纤维素组分、竹子及其中两种或更多种的组合的材料。一些实施方案提供了选自软木、橡木、硬木、桉树、***树胶、桦树、棕榈木、橡胶原木、桑木、森林管理委员会认证木材品种、椰壳纤维、黄麻、海草、麦秆及其中两种或更多种的组合的木质纤维素组分。在一些实施方案中,芯层可包括交替的竹子和软木层。
在本发明的一些实施方案中,填料至少包括两种不同类型的填料。在一些实施方案中,第一种填料选自石灰石、粘土和滑石。在一些实施方案中,第二种填料选自木质纤维素材料。在一些实施方案中,第一种填料和第二种填料可按约1:10至约10:1,可选地约1:9至约9:1,可选地约1:8至约8:1,可选地约1:7至约7:1,可选地约1:6至约6:1,可选地约1:5至约5:1,可选地约1:4至约4:1,可选地约1:3至约3:1,可选地约1:2至约2:1,和可选地约1:1的重量比存在。
在本发明的一些实施方案中,芯层包括约60重量%至约80重量%的填料。在一些实施方案中,芯层包括约65重量%至约75重量%的填料。在一些实施方案中,芯层包括约68重量%的填料。
在一些实施方案中,粘合剂包括氯乙烯均聚物、第二聚合物和增塑剂,并且填料包括石灰石和木质纤维素组分。在一些实施方案中,芯层优选包括约25重量%至约35重量%的粘合剂和约65重量%至约75重量%的填料。
在一些实施方案中,芯层进一步包括选自添加剂、稳定剂、紫外线添加剂、润滑剂、增容剂及其中两种或更多种的组合的附加组分。本发明的一些实施方案可利用热稳定剂,例如锡、铅、钡、镉和锌。塑料业中利用的内部和外部润滑剂可用于帮助加工芯层。润滑剂的实例包括:硬脂酸钙、酯、石蜡和酰胺蜡。另外,本发明也可利用起泡剂和增容剂。
在一些实施方案中,芯层包括约0重量%至约10重量%的附加组分。在一些实施方案中,芯层包括约0.01重量%至约8重量%的附加组分。在一些实施方案中,芯层包括约0.1重量%至约5重量%的附加组分。在一些实施方案中,芯层包括约1重量%至约3重量%的附加组分。
在一些实施方案中,本发明的芯层的厚度为约1mm至约15mm。在一些实施方案中,芯层的厚度为约2mm至约12mm。在一些实施方案中,芯层的厚度为约3mm至约10mm。在一些实施方案中,芯层的厚度为约4mm至约9mm。在一些实施方案中,芯层的厚度为约5mm。
在一些实施方案中,基材可进一步包括三聚氰胺浸渍纸层。在一些实施方案中,基材可进一步包括不含填料并且位于芯层上表面附近的乙烯层。一些实施方案提供了包括未经使用或回收的乙烯的乙烯层,其中所述乙烯选自聚氯乙烯、聚醋酸乙烯酯、聚苯乙烯、聚乙烯醇和聚丙烯腈。在一些实施方案中,乙烯层厚度为约0.5mm至约5mm,可选地为约1mm至约3mm,并且可选地为约1.5mm。
在一些实施方案中,基材可涂有耐磨层。在一些实施方案中,耐磨层包括树脂和耐磨颗粒,其中所述树脂可为紫外线固化树脂。在一些实施方案中,耐磨层厚度为约0.5mm至约3mm,可选地为约1mm至约2mm,并且可选地为约1.5mm。
在一些实施方案中,可向基材表面涂1、2、3、4、5、6、7、8、9或10个单独涂层。
在一些实施方案中,耐磨层包括丙烯酸酯组分。一些实施方案提供了包括约70重量%至约82重量%的丙烯酸酯组分的耐磨层。在一些实施方案中,耐磨层包括约75重量%至约80重量%的丙烯酸酯组分。
一些实施方案提供了包括聚酯丙烯酸酯、聚氨酯丙烯酸酯、不饱和脂肪族聚氨酯丙烯酸酯、环氧丙烯酸酯、硅酮丙烯酸酯、疏水性聚氨酯丙烯酸酯、疏水性丙烯酸酯、脂肪族硅酮丙烯酸酯、疏水性丙烯酸酯、胺类增效剂或其中两种或更多种的组合的丙烯酸酯组分。在一些实施方案中,丙烯酸酯组分包括丙烯酸树脂,例如脂肪族聚氨酯丙烯酸酯寡聚物、脂肪族聚氨酯丙烯酸酯、乙氧基化双酚A二甲基丙烯酸酯、丙烯酸嵌段共聚物、丙氧基化新戊二醇二丙烯酸酯、乙氧基化三羟甲基丙烷三丙烯酸酯或根据美国专利No.5,891,582的实施例7的程序形成的聚酯丙烯酸酯,所述专利特此整体并入本文。一些实施方案提出乙氧基化双酚A二甲基丙烯酸酯的寡聚化程度范围为双酚A化合物上每个羟基约2至约4个。一些实施方案提供出丙氧基化二丙烯酸酯的寡聚化程度范围为新戊二醇化合物上每个羟基约2至约4个。
在一些实施方案中,紫外线固化树脂包括单体和寡聚体。在一些实施方案中,耐磨层包括约60重量%至约90重量%的紫外线固化树脂。一些实施方案提供了包括约75重量%至约85重量%的紫外线固化树脂的耐磨层。在一些实施方案中,耐磨层包括约5重量%至约70重量%的单体。在一些实施方案中,耐磨层包括约30重量%至约45重量%的单体。在一些实施方案中,耐磨层包括约5重量%至约70重量%的寡聚体。一些实施方案提供了包括约35重量%至约45重量%的寡聚体的耐磨层。
在一些实施方案中,寡聚体选自乙氧基化双酚A二甲基丙烯酸酯、丙氧基化新戊二醇二丙烯酸酯和乙氧基化三羟甲基丙烷三丙烯酸酯。一些实施方案提出乙氧基化双酚A二甲基丙烯酸酯的寡聚化程度范围为双酚A化合物上每个羟基约2至约4个。一些实施方案提出丙氧基化二丙烯酸酯的寡聚化程度范围为新戊二醇化合物上每个羟基约2至约4个。
在一些实施方案中,单体的使用降低了固化前耐磨层的粘度并且可促进生产和涂层工艺。在一些实施方案中,单体选自丙烯酸酯、环己烷二甲醇二丙烯酸酯、三环癸烷二甲醇二丙烯酸酯、三环癸烷二甲醇二甲基丙烯酸酯、丙烯酸异冰片酯、乙氧基化三羟甲基丙烷三丙烯酸酯、环三羟甲基丙烷甲缩醛丙烯酸酯、环三羟甲基丙烷三丙烯酸酯、2-苯氧乙基丙烯酸酯、二丙二醇二丙烯酸酯、硅酮丙烯酸酯及其中两种或更多种的组合。
在一些实施方案中,丙烯酸酯组分的至少一部分包括一种或多种硅酮丙烯酸酯。一些实施方案提供了包括约1重量%至约30重量%的硅酮丙烯酸酯的耐磨层。在一些实施方案中,耐磨层包括约2重量%至约10重量%的硅酮丙烯酸酯。在一些实施方案中,耐磨层包括约3重量%至约7重量%的硅酮丙烯酸酯。
其他实施方案提供了进一步包括润滑剂的耐磨层。在一些实施方案中,耐磨层包括约1重量%至约10重量%的润滑剂。在一些实施方案中,润滑剂为蜡润滑剂。在一些实施方案中,耐磨层包括约2重量%至约10重量%的蜡润滑剂。在一些实施方案中,耐磨层包括约5重量%至约9重量%的蜡润滑剂。在一些实施方案中,耐磨层包括约6重量%至约8重量%的蜡润滑剂。在一些实施方案中,耐磨层包括约7重量%至约8重量%的蜡润滑剂。在一些实施方案中,耐磨层包括约7.5重量%的蜡润滑剂。
一些实施方案提供了包括量为约2重量%至约10重量%的硅酮丙烯酸酯和量为约2重量%至约10重量%的润滑剂的耐磨层。一些实施方案提供了包括量为约3重量%至约7重量%的硅酮丙烯酸酯和量为约5重量%至约9重量%的润滑剂的耐磨层。一些实施方案提供了包括量为约3重量%至约7重量%的硅酮丙烯酸酯和量为约6重量%至约8重量%的润滑剂的耐磨层。
在一些实施方案中,耐磨层可包括光引发剂。在一些实施方案中,光引发剂仅在电磁波谱紫外线范围内吸收。在一些实施方案中,光引发剂在电磁波谱紫外线范围外吸收。正因如此,一些实施方案提供了在位于可见光谱外或比可见光谱短,通常小于约420nm的波长下吸收辐射的光引发剂。在一些实施方案中,光引发剂对这种紫外线辐射反应以引发和诱导可固化树脂组分的固化。在一些实施方案中,耐磨层可包括约1重量%至约15重量%的光引发剂,可选地约2重量%至约6重量%的光引发剂。
在一些实施方案中,光引发剂为自由基光引发剂。在一些实施方案中,自由基光引发剂选自二苯酮、1-羟基环己基苯酮、苯基双(2,4,6-三甲基苯甲酰基)氧化膦、2,4,6-三甲基苯甲酰基二苯基氧化膦、异丙基硫杂蒽酮、1-氯-4-丙氧基-硫杂蒽酮、2,4-二乙基硫杂蒽酮、2-氯硫杂蒽酮、樟脑醌、2-乙基蒽醌、1-羟基-环己基苯酮及其中两种或更多种的组合。
在一些实施方案中,光引发剂可为二苯甲酮(例如但不限于,二苯酮)或经取代的二苯甲酮(例如α-羟基酮)。在一些实施方案中,α-羟基酮为1-羟基-环己基苯酮。
在一些实施方案中,在耐磨层中可能存在磨料。一些实施方案包括选自以下的磨料:氧化铝、萤石、磷灰石、长石、霞石正长岩、玻璃、石英、陶瓷、氮化硅、碳化硅(金刚砂)、碳化钨、碳化钛、黄玉、刚玉/蓝宝石(Al2O3)、钻石及其中两种或更多种的组合。在一些实施方案中,耐磨层包括约1重量%至约20重量%的磨料。任选地,耐磨层包括约1重量%至约10重量%的磨料。进一步任选地,耐磨层包括约1重量%至约6重量%的磨料。
在一些实施方案中,耐磨层还可能包括胺类增效剂。在一些实施方案中,耐磨层可包括约1重量%至约15重量%的胺类增效剂。在一些实施方案中,耐磨层可包括约2重量%至约6重量%的胺类增效剂。在一些实施方案中,耐磨层可包括约1重量%至约3重量%的胺类增效剂。在一些实施方案中,耐磨层可包括约2.5重量的胺类增效剂。适合的胺类增效剂包括但不限于2-乙基己基-4-二甲氨基苯甲酸酯、4-(二甲胺)苯甲酸乙酯、N-甲基二乙醇胺、2-二甲氨基乙基苯甲酸酯、4-二甲氨基苯甲酸丁氧基乙酯及其中两种或更多种的组合。
在一些实施方案中,耐磨层包括:丙烯酸酯组分、光引发剂、胺类增效剂和磨料。在一些实施方案中,按耐磨层的总重量计,耐磨层包括约65重量%至约85重量%的丙烯酸酯组分;约0.1重量%至约5重量%的光引发剂;约0.1重量%至约5重量%的胺类增效剂;和约1重量%至约15重量%的磨料。另外的实施方案提供了包括约2重量%至约3.5重量%的光引发剂的耐磨层。
其他实施方案提供了进一步包括消光剂的耐磨层。在一些实施方案中,耐磨层包括约0.1重量%至约3重量%的消光剂。在一些实施方案中,可使用无机消光剂,例如硅石。在一些实施方案中,可使用有机消光剂或无机和有机消光剂的组合。在其中采用了多种消光剂的实施方案中,消光剂可能在化学结构(即使,组成)、粒度、粒度分布、表面处理、表面积和/或孔隙率方面不同。
在一些实施方案中,耐磨层进一步包括表面活性剂。在一些实施方案中,耐磨层包括约0.1重量%至约1重量%的表面活性剂。
本发明的一些实施方案提供了一种提高地板产品的后跟耐擦性的方法,包括向基材主要表面涂上本文所述任一种耐磨层;并且将有涂层的基材暴露于至少一种辐射源。本发明的其他实施方案提供了一种提高地板产品的抗划性的方法,包括向基材主要表面涂上本文所述任一种耐磨层;并且将有涂层的基材暴露于至少一种辐射源。
还有其他实施方案提供了一种降低污垢吸到地板产品表面的程度的方法,包括向基材主要表面涂上本文所述任一种耐磨层;并且将有涂层的基材暴露于至少一种辐射源。更多其他实施方案提供了一种提高地板产品表面的清洁性的方法,包括向基材主要表面涂上本文所述任一种耐磨层;并且将有涂层的基材暴露于至少一种辐射源。
在一些实施方案中,本发明提供了一种减少地板产品的水基染色的方法,包括向基材主要表面涂上本文所述任一种耐磨层;并且将有涂层的基材暴露于至少一种辐射源。
一些实施方案提供了一种减少挥发性有机化合物从涂有本文所述任一涂层的基材排放的方法,包括:向基材主要表面涂上本文所述任一种耐磨层;并且将有涂层的基材暴露于至少一种辐射源。
在一些实施方案中,涂有耐磨层的基材提供了约85度至约120度的水接触角。在一些实施方案中,涂有耐磨层的基材提供了约6至约21dyn/cm的表面能。
在一些实施方案中,按足以提供约0.5-2mil湿润厚度的量,将耐磨层涂到基材上。在一些实施方案中,按足以提供约1mil湿润厚度的量,将耐磨层涂到基材上。
在一些实施方案中,将涂有耐磨层的基材暴露于几个辐射源。在一些实施方案中,辐射源选自红外辐射和紫外辐射。在一些实施方案中,紫外辐射源选自UVA辐射源、UVB辐射源、UVC辐射源及其中两种或更多种的组合。
一些实施方案提供了在基材上用作防护性涂层的紫外线固化组合物,例如可将地板材料制造成包括树脂和光引发剂的溶剂基或水性制剂。
在一些实施方案中,耐磨层包括可固化树脂、光引发剂、毛面剂/蜡、磨料和分散剂。在一些实施方案中,耐磨层进一步包括抗菌剂。在一些实施方案中,可固化树脂包括丙烯酸酯组分。
在一些实施方案中,耐磨层可包括至少一种聚合物毛面剂。在一些实施方案中,当耐磨层固化时,聚合物毛面剂是为了提供抛光益处,在涂层中提供的固体。在一些实施方案中,聚合物毛面剂允许干擦地板以将地板恢复到其初始外观。在一些实施方案中,这样使得地板抛光,无需添加另外的化学药品或抛光剂。
适合的聚合物毛面剂包括但不限于:聚四氟乙烯、聚乙烯、聚丙烯、改性聚乙烯、蜡聚合物、烃、基于可再生资源的生物可降解聚合物、天然蜡(例如但不限于巴西棕榈蜡、褐煤蜡、石蜡)或其组合。
在一些实施方案中,术语“润滑剂”和“聚合物毛面剂”可交换使用。
不受理论约束,据信在一些实施方案中,硅酮丙烯酸酯和聚合物毛面剂的组合有助于本发明涂层展示出更高的耐污染性。在一些实施方案中,涂层形成抗水基染料,捕获较少污垢并且易于使用干擦清洁或保持的疏水表面。
在一些实施方案中,耐磨层包括量为约0重量%至约15重量%的硅石毛面剂。在一些实施方案中,耐磨层包括约1重量%至约6重量%的硅石毛面剂。
在一些实施方案中,耐磨层还可包括至少一种分散剂。在一些实施方案中,分散剂包括丙烯酸嵌段共聚物。一些实施方案提供了包括约0.1重量%至约1重量%的分散剂的耐磨层,可选地,耐磨层包括约0.1重量%至约0.5重量%的分散剂。
一些实施方案提供了包括润湿剂的耐磨层。在一些实施方案中,润湿剂包括但不限于:硅酮或无硅酮表面活性剂、碳氟化合物表面活性剂及其组合。在一些实施方案中,耐磨层包括约0.01重量%至约5重量%的润湿剂,可选地耐磨层包括约0重量%至约1重量%的润湿剂。
在一些实施方案中,耐磨层包括抗菌剂。一些实施方案提供了包括约0重量%至约3重量%的抗菌剂,可选地约0.1至约1重量%的抗菌剂的耐磨层。
在一些实施方案中,通过合并粘合剂和填料并且加热以熔融混合制剂成分制备基材。在一些实施方案中,然后可使用本领域已知的加工方法,包括但不限于压光、挤出、铸造、固结和层压,将熔融混合制剂形成层以产生地板结构。在一些实施方案中,可使用高强度、“挤出机式”搅拌器混合PVC和其他聚合物以将所述制剂加工成基材。一些实施方案提出基材可能均匀,并且根据其在地板结构中的位置和功能,可能经填充或未填充。在其他实施方案中,熔融混合制剂可形成球粒、小片或颗粒,其中所述球粒、小片或颗粒稍后可用于共挤出工艺中以生产芯层材料。在一些实施方案中,共挤出工艺利用共同连接到一个模具的两个挤出机,尽管本发明可利用其他已知排列。
在一些实施方案中,将耐磨层涂到基材的上表面。在一些实施方案中,耐磨层固化并形成暴露于紫外光后,赋予更高耐污染性、更高耐擦性、更高抗划性和/或使用干擦保养恢复地板的能力的涂层。
在一些实施方案中,地板***进一步包括具有上表面和下表面的垫层。一些实施方案提出垫层位于基材和底层地板之间。在一些实施方案中,底层地板包括但不限于混凝土、木材、胶合板或定向刨花板。在一些实施方案中,垫层的厚度为约0.5mm至约5mm,可选地为约1mm至约3mm,并且可选地为约1.5mm。
在一些实施方案中,垫层可包括一层或多层,包括性能增强层。在一些实施方案中,垫层可包括亲水性或疏水性材料。在一些实施方案中,垫层包括木质纤维素材料和聚合材料例如竹子、软木、石蜡、发泡聚酯及其中两种或更多种的组合。本发明的一些实施方案提供了包括竹子和软木的垫层。一些实施方案提出竹子和软木呈交替层组装。
在一些实施方案中,垫层与基材预组装在一起。一些实施方案提供了涂在基材下表面、垫层上表面或二者的胶粘剂。在一些实施方案中,垫层上表面压在基材下表面上,从而在安装地板***之前将基材下表面粘附到垫层上表面。
在其他实施方案中,垫层可与基材分开提供。一些实施方案提出用胶粘剂预先胶合垫层上表面并将离型板置于胶粘剂上,或用胶粘剂预先胶合基材下表面并将离型板置于胶粘剂上。在一些实施方案中,离型板为包括聚合物或硅涂层的纸或离型膜。在一些实施方案中,在安装地板***时从垫层的预先胶合上表面去除离型板,然后使垫层的预先胶合上表面与基材下表面接触,从而将基材和垫层粘合在一起。在一些实施方案中,在安装地板***时从基材的预先胶合下表面去除离型板,并且使基材的预先胶合下表面与垫层上表面接触,从而将基材和垫层粘合在一起。
在一些实施方案中,胶粘剂包括压敏型胶粘剂。在一些实施方案中,胶粘剂包括通过接触和压力,与底层地板和基材产生结合的胶粘剂。压敏型胶粘剂可包括有粘性并且保持粘性的胶粘剂,最初有粘性而在与地板材料接触后***的胶粘剂,和非粘性的胶粘剂。这种胶粘剂包括有机溶剂基、水基和热熔性胶粘剂。例如,有机溶剂基和水基胶粘剂包括但不限于丁苯橡胶、苯乙烯异戊二烯橡胶、聚异丁烯橡胶、苯乙烯-异戊二烯-苯乙烯(“SIS”)和苯乙烯-丁二烯-苯乙烯(“SBS”)嵌段共聚物橡胶、天然橡胶、丙烯酸均聚物和共聚物、醋酸乙烯酯共聚物、聚酯、聚氨酯和沥青。热熔性压敏型胶粘剂包括但不限于无定形聚丙烯、聚异丁烯、乙烯醋酸乙烯酯、聚酯、乙烯丙烯酸共聚物、SIS和SBS嵌段共聚物橡胶和聚氨酯。另外,热熔性胶粘剂还包括接触反应性材料,例如Kobe等的美国专利No.5,888,335中描述的接触反应性材料。这些有机溶剂基、水基和热熔性胶粘剂聚合物可与低分子量增粘树脂,例如脂肪烃和芳香烃或松香酯共混。
在一些实施方案中,胶粘剂包括两部分***。在一些实施方案中,胶粘剂的一部分涂到垫层上而第二部分涂到表面遮盖物的背面,以致当表面遮盖物与垫层上的第一部分接触时,发生胶粘化学反应以使表面遮盖物与垫层化学结合。胶粘剂层可为大体上均匀层或不连续。例如,胶粘剂可呈珠粒形式涂到垫层上。
在一些实施方案中,一层或多层性能增强层可置于基材和垫层之间或垫层和底层地板之间以改变和/或增强地板***的各种性质。一些实施方案提出性能增强层包括固体或发泡聚合物例如聚酯。
在本发明的一些实施方案中,通过位于基材上用于将基材邻接到相邻基材的锁定装置安装地板***。在一些实施方案中,锁定装置包括榫舌和凹槽或推入式配合锁。一些榫舌和凹槽木地板***可“浮动”安装,意味着其安装不需要复杂的插钉或胶合,以致其可由消费者容易地安装,无需雇用专业的安装人员。由于榫舌和凹槽互锁接合***的设计,浮动安装是可能的。使得能够浮动安装木地板的榫舌和凹槽互锁接合***通常称为“棘爪(click)***”。
通常理解,“棘爪***”指包括在地板四个侧边(边缘)形成的两个榫舌和两个凹槽的互锁接合***。一般情况是,互锁榫舌/凹槽的地板长边(纵向侧边)和互锁榫舌/凹槽的地板横边(对接侧边)可能具有不同形状。传统棘爪***设计为水平和垂直锁定相邻地板到位,以防相邻地板在未用任何胶或钉安装后相互水平和/或垂直分离。另外,传统棘爪***可容易地开锁,使得使用者能够拆卸地板,然后在不同位置重新安装。传统棘爪***具有不同形式/类型,包括但不限于卡扣锁定(snap-lock)***、可旋转锁定***、下落锁定(drop-lock)***等,其中任一种通常可提供有或无单独锁定元件。
在一些实施方案中,芯层产生不仅具有优良湿度相关尺寸稳定性,而且具有温度相关尺寸稳定性的基材。仅包括氯乙烯均聚物的地板***将产生Tg值高达200℉的芯层。在环境温度下,芯层将呈玻璃态。所得地板***在室温下室内经常使用期间将很可能僵硬。然而,本发明提供了表现出低至100℉的Tg的粘合剂组合物。所得芯层很可能更具柔性并且非常适合室内使用或寒冷天气环境。
除在较低温度下具有优良尺寸稳定性外,本发明还提供了在较高温度下表现出优良尺寸稳定性的芯层。使用具有仅包括氯乙烯均聚物的粘合剂的芯层的地板***在180℉温度下表现出小于零的热膨胀系数(CTE)。温度升高时,芯层将迅速皱缩,从而引起地板***收缩并翘曲。然而,本发明的发明组合物提供了在180℉下CTE值至少为零,并且在较高温度下不会变形的芯层。因此,本发明的地板***在至少180℉温度下维持了尺寸稳定性,从而提供了更多适合的地板应用。
而且,在一些实施方案中,Tg值越低提供的柔性越强,不会破坏尺寸稳定性,因为可向芯层添加更多量的填料,从而确保芯层中的恰当机械稳定性。
将通过具体实例更加详细地描述本发明。提供下列实例是为了说明的目的,而非旨在以任何方式限制本发明。本领域的技术人员将易于识别各种非关键参数,其可经改变或修改而产生基本上相同的结果。
实施例
实施例1
下面在表1中提供了本发明示例性地板***的组成,并且下面在表2中提供了比较地板***的组成。
表1
表2
实施例2
表3(下面)描述了由本发明的示例性基材和比较基材的热稳定性评估生成的数据。在加工方向测量了基材的尺寸。然后将基材暴露于约180℃的温度约6h。然后测量处理后的加工方向尺寸。具有适合热稳定性的基材展示出小于或等于0.1%的加工方向尺寸变化。表3所述数据证明,本发明的具有创造性的粘合剂:填料比的基材提供了适当水平的尺寸稳定性,而不具有发明粘合剂:填料比的比较基材未提供适当水平的尺寸稳定性。
表3
实施例3
在3点弯曲试验中评估了本发明的示例性基材和比较基材,以计算其弯曲模量。弯曲模量越高,基材越硬。3点弯曲试验期间,使用Instron测试器,按0.5英寸/分钟的十字头速度施加压力,基材跨度6英寸。施加压力时,使基材暴露于越来越高的温度并且计算特定温度下的弯曲模量。
3点弯曲试验的结果进一步证明本发明的发明基材提供了出乎意料的尺寸稳定性。具体地,本发明的示例性基材在试验期间变得更具柔性,而比较基材变得如此脆,以致其50%破裂。
本专利文件中提到的任何专利、专利申请或印刷出版物,包括书籍在内,旨在特此以引用的方式整体并入。
正如本领域的技术人员将认识到那样,在不背离本发明精神的前提下,可对本文所述实施方案做许多变化和修改。其意图是,所有这种改变均在本发明的范围之内。
Claims (15)
1.一种地板***,其包括:
底层地板;和
位于所述底层地板上的地板产品,所述地板产品包括:
基材,其中所述基材具有涂有耐磨层的上表面,所述基材包括芯层,所述芯层包括熔融混合的混合物,其包含:
粘合剂,所述粘合剂包括聚合物和增塑剂,所述聚合物的Tg介于90℉和150℉之间,并且选自聚对苯二甲酸乙二醇酯、丙烯腈-丁二烯-苯乙烯、聚丙烯、聚乙烯、聚酯、丙烯酸酯、硅氧烷、铂催化的硅酮中的一种或两种或更多种的组合;所述增塑剂的含量范围为基于所述芯层的总重量的1重量%至12重量%;和
填料,所述填料包括石灰石、粘土、滑石中的至少一种粉末;以及
垫层,其位于所述基材和所述底层地板之间;
其中所述粘合剂和填料按1:1至1:3的重量比提供。
2.根据权利要求1所述的地板***,其中所述增塑剂选自邻苯二甲酸丁苯酯、邻苯二甲酸二异壬酯、对苯二甲酸二辛酯、二异壬基环己烷、苯甲酸酯中的一种或两种或更多种的组合。
3.根据权利要求1所述的地板***,其中所述填料还包括选自木质纤维素组分、竹子中的一种或两种的组合的材料。
4.根据权利要求1所述的地板***,其中所述垫层包括疏水性材料。
5.根据权利要求4所述的地板***,其中所述疏水性材料选自:软木、石蜡中的一种或两种的组合。
6.根据权利要求1所述的地板***,其中所述耐磨层包括UV可固化树脂。
7.根据权利要求1所述的地板***,其中所述耐磨层包括耐磨颗粒。
8.根据权利要求1所述的地板***,其中所述耐磨层的厚度为1.5mm。
9.根据权利要求1所述的地板***,其中所述芯层包括20重量%至40重量%的粘合剂。
10.根据权利要求9所述的地板***,其中所述芯层包括60重量%至80重量%的填料。
11.根据权利要求1所述的地板***,其中所述基材进一步包括使所述基材与相邻基材邻接的锁定装置。
12.根据权利要求1所述的地板***,其中所述芯层的厚度为1mm至15mm。
13.根据权利要求10所述的地板***,其中所述芯层包括10重量%至40重量%的聚合物。
14.根据权利要求1所述的地板***,其中,存在的所述粘合剂的含量范围是基于所述芯层的总重量的25重量%至35重量%;其中,存在的所述填料的含量范围是基于所述芯层的总重量的65重量%至75重量%。
15.根据权利要求14所述的地板***,其中,所述填料是无机填料;其中,所述增塑剂选自邻苯二甲酸丁苯酯、邻苯二甲酸二异壬酯、对苯二甲酸二辛酯、二异壬基环己烷、苯甲酸酯中的一种或两种或更多种的组合。
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AU2019393853A1 (en) * | 2018-12-04 | 2021-07-01 | I4F Licensing Nv | Decorative panel, and decorative floor covering consisting of said panels |
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