CN108262932B - 一种石塑地板的生产工艺及生产地板基材的模头 - Google Patents

一种石塑地板的生产工艺及生产地板基材的模头 Download PDF

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CN108262932B
CN108262932B CN201711473661.6A CN201711473661A CN108262932B CN 108262932 B CN108262932 B CN 108262932B CN 201711473661 A CN201711473661 A CN 201711473661A CN 108262932 B CN108262932 B CN 108262932B
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张国良
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Taizhou Huangyan Jingwei Mould Co ltd
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Abstract

本发明特指一种石塑地板的生产工艺及生产地板基材的模头,属于挤压成型模头及塑胶地板生产技术领域，石塑地板包括耐磨层、玻璃纤维层和基材，所述基材由80份PVC，210份钙粉，8.3份钙锌稳定剂，4.8份氯化聚乙烯，2.3份丙烯酸酯类和1.6份聚乙烯蜡组成。生产地板基材的模头，包括上模和下模，模头一端为进料口，另一端为成型口，上模上设有活动嘴，上模与下模合模形成挤压流道，活动嘴与下模合模形成成型腔，挤压流道包括预热段和挤压段，预热段和挤压段均向模腔两侧延伸，成型腔内设有一段发泡腔和缓冲腔，发泡腔呈水滴状，且靠近成型口。本发明通过该模头能够提高地板基材的产量和质量，从而保证石塑地板能够达到防水环保的要求。

Description

一种石塑地板的生产工艺及生产地板基材的模头
技术领域
本发明属于挤压成型模头及塑胶地板生产技术领域，特指一种石塑地板的生产工艺及生产地板基材的模头。
背景技术
传统的复合地板在防水防潮上比较差，容易膨胀变形，不利于清洁，而且生产工艺复杂，生产过程中必须使用胶水，使成型后的地板甲醛含量偏高，具有一定的污染性，对人体健康不利，不环保，不可循环利用，另一方面，可塑性不强，可加工性差，吸音和脚感方面，效果也不佳，在防火阻燃性能上也不足，越来越无法满足市场的需求，相信在不久的将来会逐渐被市场所淘汰。另外，在地板基材的生产上，基本上都采用模头进行挤压成型，而现有的模头基本上都能满足正常的生产需求，但是依然存在一定的缺陷，主要集中在以下几点：1、生产效率低，产量难以提高；2、流道清洗周期短，影响生产；3、容易漏胶；4、成型的基材厚度不够均匀。而地板基材作为复合地板的核心材料，直接影响复合地板的生产和质量。
发明内容
本发明的目的是提供一种石塑地板的生产工艺及生产地板基材的模头，通过该模头能够提高地板基材的产量和质量，从而保证石塑地板能够达到防水环保的要求。
本发明的目的是这样实现的：一种石塑地板的生产工艺，其中，石塑地板包括耐磨层、玻璃纤维层和基材，按重量份计，所述耐磨层由95份PVC，2.2份钙锌稳定剂，23份二辛酯，1.6份环氧大豆油和0.4份丙烯酸酯共聚物组成；所述基材由80份PVC，210份钙粉，8.3份钙锌稳定剂，4.8份氯化聚乙烯，2.3份丙烯酸酯类和1.6份聚乙烯蜡组成。
据上所述的一种石塑地板的生产工艺，其中，所述耐磨层上还设置有UV涂层。
据上所述的一种石塑地板的生产工艺，其中，所述基材中添加有着色剂。
据上所述的一种石塑地板的生产工艺，包括如下步骤：
步骤一、配料：将耐磨层和基材按上述组份进行配制，并充分混合；
步骤二、造粒：将耐磨层和基材混合好的原料，分别单独加入造粒机中进行造粒；
步骤三、挤压成型：将步骤二中的基材颗粒加入到挤出机中，预热温度为200℃-220℃，螺杆送料装置处的温度为215℃-230℃，挤出模头内的温度为230℃-250℃，最后从挤出模头的成型口挤出，形成基材；同时，将步骤二中的耐磨层颗粒加入到另外的挤出机中，预热温度为220℃-240℃，螺杆送料装置处的温度为225℃-245℃，挤出模头内的温度为240℃-260℃，最后从挤出模头的出料口挤出，形成耐磨层片材；
步骤四、热压：通过三辊或四辊压延机将耐磨层片材，玻璃纤维层和基材，进行一次性加热贴合，压制成初级地板板材，加热温度控制在150℃-180℃之间；
步骤五、淋膜：将初级地板板材通过UV滚涂机进行涂装，在耐磨层的表面形成一层UV涂层；
步骤六、回火定型：将地板放入回火炉中进行回火处理，回火温度控制在100℃-150℃之间；
步骤七、冲切：将地板冲切成要求的规格大小；
步骤八、包装：将冲切好的地板进行包装，并放置于22℃-25℃的保温房中静置7天左右。
据上所述的生产地板基材的模头，包括上模和下模，两者通过两侧的模架固定，模头一端为进料口，另一端为成型口，所述上模上设置有活动嘴，所述上模与下模合模形成挤压流道，所述活动嘴与下模合模形成成型腔，所述挤压流道包括预热段和挤压段，所述预热段和挤压段均向模腔两侧延伸，所述预热段的横截面呈锥形，所述挤压段呈扁平状，基材用料在挤压段平铺开后，使基材用料受热均匀，提高熔融状态下的流动性，所述成型腔一侧为所述成型口，另一侧与所述挤压段连通，所述活动嘴上设置有调节螺栓，通过调节螺栓能够调节成型腔的厚度，可以控制地板基材成型的厚度，并确保地板基材的厚度均匀。
据上所述的生产地板基材的模头，其中，所述成型腔内设置有一段发泡腔和缓冲腔，所述发泡腔呈水滴状，且靠近所述成型口，发泡腔能够对基材用料进行预发泡，提高成型质量，所述缓冲腔与所述挤压段连接，且横截面呈锥形。
据上所述的生产地板基材的模头，其中，所述发泡腔与缓冲腔之间的腔体呈扁平状，发泡腔至成型口的腔体呈扁平状，两段扁平状的腔体能够对熔融状态的基材用料进行挤压拉伸调整，能够提高成型后的基材整体的均匀性，提高了基材成型的质量。
据上所述的生产地板基材的模头，其中，所述挤压段与成型腔对接处设置有弯流腔，所述弯流腔一侧设置有调节块，所述上模的外壁设置有调节杆，所述调节杆与所述调节块连接，弯流腔能够对熔融状态的基材用料进行正反两个方向的两次挤压拉伸，能够对基材用料进行调质，提高其性能。
据上所述的生产地板基材的模头，其中，所述上模和下模内均设置有若干加热棒，所述加热棒从进料口指向成型口，能够确保各腔体受热均匀。
本发明相比现有技术突出且有益的技术效果是：本发明中的模头能够提高产量，达到24小时生产30吨，流道清洗周期延长，只需一个月清洗一次，减少了对生产的影响，而且密封性好，不会漏胶，地板基材成型后，其厚度均匀，产品质量高；以该模头生产的地板基材为基础进行石塑地板的生产，得到的产品防水、防潮，从根本解决了木质产品和传统复合地板对潮湿和多水环境中吸水受潮后容易腐烂、膨胀变形的问题；可塑性强，能非常简单的实现个性化造型，充分体现个性风格；高环保性、无污染、无公害、可循环利用，产品不含苯及甲醛，为环保产品，可循环利用大大节约了木材使用量，适合可持续发展的国策，造福社会；高防火性，能有效阻燃，防火等级达到B1级，遇火自熄，不产生任何有毒气体；可加工性好，可订、可刨、可锯、可钻、表面可上漆；不龟裂，不膨胀，不变形，无需维修与养护，便于清洁，节省后期维修和保养费用；吸音和脚感效果好。
附图说明
图1是本发明中基材成型模头的立体结构示意图；
图2是本发明的中基材成型模头的主视示意图；
图3是图2中A-A处的剖视示意图Ⅰ；
图4是图3中Ⅰ处的局部放大示意图；
图5是图2中A-A处的剖视示意图Ⅱ
图6是本发明中基材成型模头的侧视示意图；
图7是图6中B-B处的剖视示意图；
图8是图6中C-C处的剖视示意图；
图中：10-上模，11-下模，12-模架，13-进料口，14-加热棒，15-活动嘴，16-调节螺栓，17-预热段，18-挤压段，19-成型腔，20-发泡腔，21-缓冲腔，22-成型口，23-弯流腔，24-调节块，25-调节杆，26-螺栓。
具体实施方式
下面结合附图以具体实施例对本发明作进一步描述，参见图1—7：一种石塑地板，其中，石塑地板包括耐磨层、玻璃纤维层和基材，按重量份计，所述耐磨层由以下组份组成，95份PVC，2.2份钙锌稳定剂，23份二辛酯，二辛酯是一种塑化剂，混合性能好，增塑效率高，挥发性较低，低温柔软性较好，耐水抽出，电气性能高，耐热性和耐候性良好，1.6份环氧大豆油，能够大幅提高PVC的耐候性、耐热性、透明性，0.4份丙烯酸酯共聚物，加快PVC的塑化过程，改进热塑性熔体的流变性能，改善热弹性状态下熔体力学性能；所述基材由以下组份组成，80份PVC，210份钙粉，8.3份钙锌稳定剂，4.8份氯化聚乙烯，氯化聚乙烯能够提高PVC的耐侯性、耐臭氧、耐化学药品及耐老化性能，使PVC具有良好的耐油性、阻燃性及着色性能，2.3份丙烯酸酯类，能够促进PVC塑化功能，降低塑化温度，大大改善PVC的加工性能，1.6份聚乙烯蜡，聚乙烯蜡具有润滑作用，改善了PVC的流动性，提高了挤压成型速率，便于挤压成型。
将基材所需的组份进行混合造粒后，通过挤出机进行挤出成型，挤出机上所使用的模头，包括上模10和下模11，两者通过两侧的模架12固定，同时，在上模10上垂直设置有螺栓26，螺栓26将上模10和下模11进一步锁紧，模头一端为进料口13，进料口为圆形，直径为119-120mm，另一端为成型口22，成型口的厚度为0.5-1mm，所述上模10和下模11内均设置有若干加热棒14，所述加热棒14从进料口13指向成型口22，能够确保各腔体受热均匀。所述上模10上设置有活动嘴15，所述上模10与下模11合模形成挤压流道，所述活动嘴15与下模11合模形成成型腔19，所述挤压流道包括预热段17和挤压段18，所述预热段17和挤压段18均向模腔两侧延伸，所述预热段17的横截面呈锥形，与进料口连接的部分呈圆柱形，直径为89-90mm，锥形嘴的夹角为57°-58°，所述挤压段18呈扁平状，其厚度为5.5-6.2mm，基材用料在挤压段18平铺开后，使基材用料受热均匀，提高熔融状态下的流动性，所述成型腔19一侧为所述成型口22，另一侧与所述挤压段18连通，所述活动嘴15上设置有调节螺栓16，通过调节螺栓16能够调节成型腔19的厚度，可以控制地板基材成型的厚度，并确保地板基材的厚度均匀，上述尺寸的设置，能确保产品成型质量。
所述成型腔19内设置有一段发泡腔20和缓冲腔21，所述发泡腔20呈水滴状，且靠近所述成型口22，发泡腔进料处的夹角为5.02°-5.5°，出料处的夹角为15.3°-16°，发泡腔20能够对基材用料进行预发泡，提高成型质量，所述缓冲腔21与所述挤压段18连接，且横截面呈锥形，其夹角为6.3°-7°
所述发泡腔20与缓冲腔21之间的腔体呈扁平状，厚度为1-1.2mm，发泡腔20至成型口22的腔体呈扁平状，厚度为0.5-1mm，两段扁平状的腔体能够对熔融状态的基材用料进行挤压拉伸调整，能够提高成型后的基材整体的均匀性，提高了基材成型的质量。
所述挤压段18与成型腔19对接处设置有弯流腔23，其腔体厚度为5.5-6.2mm，所述弯流腔23一侧设置有调节块24，所述上模10的外壁设置有调节杆25，所述调节杆25与所述调节块24连接，弯流腔23的进口端和出口端呈拐角，两处拐角的角度为127°-128°，熔融状态的基材用料从进口端进入时，受到一次挤压拉伸，经过弯流腔23再到出口端，受到第二次的反向挤压拉伸，熔融状态的基材用料进行正反两个方向的两次挤压拉伸后，能够对基材用料进行调质，提高其性能。
在挤出机挤压的过程中，预热温度为200℃-220℃，螺杆送料装置处的温度为215℃-230℃，到挤出模头内，所述预热段17的温度为230℃，所述挤压段18的温度为240℃，所述成型腔19的温度为250℃，最后从挤出模头的成型口22挤出，形成基材。
本发明中石塑地板具体的生产步骤为：步骤一、配料：将耐磨层和基材按上述组份进行配制，并充分混合，其中基材所用原料还可加入适量的着色剂，按要求生产出不同颜色的基材；
步骤二、造粒：将耐磨层和基材混合好的原料，分别单独加入造粒机中进行造粒；
步骤三、挤压成型：将步骤二中的基材颗粒加入到挤出机中，预热温度为200℃-220℃，该区间温度均可，属于正常误差范围，螺杆送料装置处的温度为215℃-230℃，该区间温度均可，属于正常误差范围，挤出模头内的温度为，所述预热段的温度为230℃，所述挤压段的温度为240℃，所述成型腔的温度为250℃，最后从挤出模头的成型口挤出，形成基材；同时，将步骤二中的耐磨层颗粒加入到另外的挤出机中，预热温度为220℃-240℃，该区间温度均可，属于正常误差范围，螺杆送料装置处的温度为225℃-245℃，该区间温度均可，属于正常误差范围，挤出模头内的温度为，所述预热段的温度为240℃，所述挤压段的温度为250℃，所述成型腔的温度为260℃，最后从挤出模头的出料口挤出，形成耐磨层片材；
步骤四、热压：通过三辊或四辊压延机将耐磨层片材，玻璃纤维层和基材，进行一次性加热贴合，压制成初级地板板材，加热温度控制在150℃-180℃之间，该区间温度均可，属于正常误差范围；
步骤五、淋膜：将初级地板板材通过UV滚涂机进行涂装，在耐磨层的表面形成一层UV涂层；
步骤六、回火定型：将地板放入回火炉中进行回火处理，回火温度控制在100℃-150℃之间，该区间温度均可，属于正常误差范围；
步骤七、冲切：将地板冲切成要求的规格大小；
步骤八、包装：将冲切好的地板进行包装，并放置于22℃-25℃的保温房中静置7天左右。
上述实施例仅为本发明的较佳实施例，并非依此限制本发明的保护范围，故：凡依本发明的结构、形状、原理所做的等效变化，均应涵盖于本发明的保护范围之内。

Claims (4)

1.一种石塑地板的生产工艺，其特征在于：石塑地板包括耐磨层、玻璃纤维层和基材，按重量份计，所述耐磨层由95份PVC，2.2份钙锌稳定剂，23份二辛酯，1.6份环氧大豆油和0.4份丙烯酸酯共聚物组成；所述基材由80份PVC，210份钙粉，8.3份钙锌稳定剂，4.8份氯化聚乙烯，2.3份丙烯酸酯类和1.6份聚乙烯蜡组成；
其中，包括如下步骤：
步骤一、配料：将耐磨层和基材按上述组份进行配制，并充分混合；
步骤二、造粒：将耐磨层和基材混合好的原料，分别单独加入造粒机中进行造粒；
步骤三、挤压成型：将步骤二中的基材颗粒加入到挤出机中，预热温度为200℃-220℃，螺杆送料装置处的温度为215℃-230℃，挤出模头内的温度为230℃-250℃，最后从挤出模头的成型口挤出，形成基材；同时，将步骤二中的耐磨层颗粒加入到另外的挤出机中，预热温度为220℃-240℃，螺杆送料装置处的温度为225℃-245℃，挤出模头内的温度为240℃-260℃，最后从挤出模头的出料口挤出，形成耐磨层片材；
步骤四、热压：通过三辊或四辊压延机将耐磨层片材，玻璃纤维层和基材，进行一次性加热贴合，压制成初级地板板材，加热温度控制在150℃-180℃之间；
步骤五、淋膜：将初级地板板材通过UV滚涂机进行涂装，在耐磨层的表面形成一层UV涂层；
步骤六、回火定型：将地板放入回火炉中进行回火处理，回火温度控制在100℃-150℃之间；
步骤七、冲切：将地板冲切成要求的规格大小；
步骤八、包装：将冲切好的地板进行包装，并放置于22℃-25℃的保温房中静置7天左右；
其中，生产石塑地板基材的模头包括上模(10)和下模(11)，两者通过两侧的模架(12)固定，模头一端为进料口(13)，另一端为成型口(22)，其特征在于：所述上模(10)上设置有活动嘴(15)，所述上模(10)与下模(11)合模形成挤压流道，所述活动嘴(15)与下模(11)合模形成成型腔(19)，所述挤压流道包括预热段(17)和挤压段(18)，所述预热段(17)和挤压段(18)均向模腔两侧延伸，所述预热段(17)的横截面呈锥形，所述挤压段(18)呈扁平状，所述成型腔(19)一侧为所述成型口(22)，另一侧与所述挤压段(18)连通，所述活动嘴(15)上设置有调节螺栓(16)，通过调节螺栓(16)能够调节成型腔(19)的厚度；
其中，所述成型腔(19)内设置有一段发泡腔(20)和缓冲腔(21)，所述发泡腔(20)呈水滴状，且靠近所述成型口(22)，所述缓冲腔(21)与所述挤压段(18)连接，且横截面呈锥形；
所述发泡腔(20)与缓冲腔(21)之间的腔体呈扁平状，发泡腔(20)至成型口(22)的腔体呈扁平状；
所述挤压段(18)与成型腔(19)对接处设置有弯流腔(23)，所述弯流腔(23)一侧设置有调节块(24)，所述上模(10)的外壁设置有调节杆(25)，所述调节杆(25)与所述调节块(24)连接。
2.根据权利要求1所述的一种石塑地板的生产工艺，其特征在于：所述耐磨层上还设置有UV涂层。
3.根据权利要求1所述的一种石塑地板的生产工艺，其特征在于：所述基材中添加有着色剂。
4.根据权利要求1所述的一种石塑地板的生产工艺，其特征在于：所述上模(10)和下模(11)内均设置有若干加热棒(14)，所述加热棒(14)从进料口(13)指向成型口(22)。
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