CN115916539B - 瓷砖制造方法 - Google Patents

瓷砖制造方法 Download PDF

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CN115916539B
CN115916539B CN202180017347.5A CN202180017347A CN115916539B CN 115916539 B CN115916539 B CN 115916539B CN 202180017347 A CN202180017347 A CN 202180017347A CN 115916539 B CN115916539 B CN 115916539B
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lvt
surface layer
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positioning guide
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N·赫森
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R Tek Manufacturing Co ltd
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Abstract

本发明提供了一种生产用于模块化地板***的互连多层LVT瓷砖的方法，所述方法包括以下步骤：a)通过注射成型形成具有至少一个定位引导件的塑料材料基板；b)用粘合剂涂覆LVT表面层的背面；c)将LVT表面层与基板的顶表面对准，使得LVT表面层邻接基板的定位引导件或每个定位引导件；d)将基板和LVT表面层一起压轧，以形成超大的坯料；以及e)使用冲头和压模工具从超大的坯料中冲出互锁形状。

Description

瓷砖制造方法
本发明涉及地板覆盖物制造领域，特别地，涉及用于生产用于模块化地板***的互连瓷砖(例如，互锁多层LVT瓷砖)的方法。
背景技术
由塑料材料制造看起来像木头、陶瓷或石材的地板覆盖物的技术是众所周知的。例如，豪华乙烯基地板(LVT)涉及由一系列层制成的异质聚氯乙烯(PVC)瓷砖。稳定层帮助产品放平和达到平衡，高密度乙烯基层提供保护和抗冲击性，装饰层赋予产品逼真的木材、陶瓷或石材效果，并且耐磨层保护地板设计免受磨损。使用热和压力对层进行叠加和组合。
存在各种已知的地板覆盖物，它们可由可彼此机械连接的元件构造。所述元件通常是面板，所述面板包括矩形区域，并且沿着它们的周边，即在它们的周边处，具有用于连接到相邻面板的连接装置。US10,344,485公开了一种地板元件，所述地板元件具有至少两层软木基材料并具有卡扣式连接，即其中地板元件首先成角度纵向卡入先前铺设的地板元件中，然后倾斜进入水平位置的连接。地板元件还具有沿较短边的连接装置，所述连接装置容许相邻地板元件的垂直***。这允许将地板元件沿较短边竖直向下***到先前铺设的地板元件中。
其他互锁地板覆盖物通常在其***边缘上具有交替的突出舌片和凹口，例如燕尾连接。目前市场上具有此类燕尾连接的互锁层压板和LVT地板覆盖物是通过共挤出和热压方法制备的。
本发明的目标是提供一种生产用于模块化地板***的互锁LVT地板覆盖物的新的、改进的方法，该方法比先前可实现的方法更快、更便宜、更有效和更方便。
发明内容
本发明涉及一种使用注射成型生产互连LVT地板覆盖物(诸如，用于模块化地板***的互锁多层LVT瓷砖)的方法。
因此，本发明的第一方面提供了一种生产用于模块化地板***的互连多层LVT瓷砖的方法，该方法包括以下步骤：
a)通过注射成型形成具有至少一个定位引导件的塑料材料基板；
b)用粘合剂涂覆LVT表面层的背面；
c)将LVT表面层与基板的顶表面对准，使得LVT表面层邻接基板的定位引导件或每个定位引导件；
d)将基板和LVT表面层一起压轧，以形成超大的坯料；以及
e)使用冲头和压模工具从超大的坯料中冲出互锁形状。
定位引导件用于对准基板的顶表面上的LVT表面层。
定位引导件优选地是在基板的顶表面的周边的一部分处，特别优选地在其一个或多个转角处的直立区段。
定位引导件可能是连续的或不连续的。也就是说，它可能是坚固的直立墙，或者它可替代地包括彼此并排的多个直立柱。
基板优选地是四边形的，例如正方形，优选地在两个相邻的转角处具有定位引导件。
优选地，塑料材料是热塑性弹性体。替代地，塑料材料由PVC形成，特别优选由回收的PVC形成，尽管可使用赋予必要的抗冲击性的其他塑料材料。
合适的LVT表面层具有至少一个PVC层、印刷层和基于三聚氰胺树脂、聚氨酯、聚对苯二甲酸乙二醇酯、聚丙烯和PVC中的任何一种或多种的耐磨层。
在优选的实施方案中，步骤b)中使用的粘合剂是热熔聚氨酯粘合剂。然而，这不应被认为是限制性的并且可使用合适的替代方案。
在步骤b)中优选使用辊涂机将粘合剂施加到LVT表面层。
在优选实施方案中，步骤d)中的压轧是使用轧辊机实现的
地板覆盖物的厚度足以赋予地板覆盖物必要的弯曲强度和抗冲击性，优选地其中地板覆盖物厚度在约6mm至约10mm厚的范围内，优选地为约6.5mm至约9.5mm厚，例如7.5mm厚。
互锁形状优选地包括在基板的相邻边处的多个突出的舌片和凹口，特别优选地是燕尾连接。
在优选实施方案中，基板的厚度在从约3mm至约8mm的范围内，优选地从约4mm至约7mm，例如约5mm厚。
在优选实施方案中，LVT表面层的厚度在约2mm至约3mm的范围内，例如约2.5mm厚。
附图说明
现在将参考附图仅以举例的方式来描述本发明的某些优选实施方案，在附图中：
图1A示出了通过共挤出而不是分层形成的现有技术瓷砖的透视图；
图1B示出了图1A的现有技术的侧视图；
图2A示出了在根据本发明的方法中使用的优选基板的透视图；
图2B示出了图2A的基板的侧视图；
图2C示出了图2A和图2B的基板的平面图；
图3示出了在根据本发明的方法中形成的优选坯料的示意性透视图；并且
图4A至图4C示出了根据本发明的优选方法的示意图，包括相应侧视图的放大区段。
具体实施方式
将参考附图详细描述本发明的各种实施方案，其中贯穿几个视图，相同的附图标记表示相同的部分和组件。
参考附图，描述了形成互锁瓷砖的优选方法，该方法包括形成基板2的初始步骤，该基板在基板2的顶表面5的两个转角处具有直立定位引导件4。在图2A至图2C中示出了该优选基板2。
注射成型工具可装配到注射成型机并适当地操作以形成基板2。基板2在成型时从机器中移除并允许其冷却。此类注射成型工具在机器板之间装配到机器，并使用模具夹具进行紧固。然后将呈各种颜色中的任何一种的柔性PVC真空馈送到成型机的料斗，并且重力馈送到机器的机筒中，在此所述柔性PVC在180℃-190℃之间熔融。注射成型机被设置成允许机筒内的螺杆拾取足够的熔融材料，然后通过机筒的喷嘴以预设的速度和压力将其注射到闭合的模具中。模具在预设的时间内保持关闭以允许冷却。然后，模具打开并且具有直立定位引导件4的基板2被手动或自动地从模具中弹出。然后，将该模制的基板2堆叠在冷却架上约24小时。应当理解，可根据要求或视需要模制基板2和定位引导件4的尺寸。
接着，如图4A中示意性地示出，粘合剂A施加到LVT表面层3的底表面。通过操作辊涂机(未示出)以将粘合剂A施加到LVT表面层3来执行此类步骤。粘合剂A可能是热熔聚氨酯粘合剂或任何其他合适的粘合剂，并且LVT表面层3可能包括PVC背衬层、具有期望的表面光洁度或瓷砖效果(诸如，石材，陶瓷、木材等)的印刷中间层以及透明的PVC顶层。LVT表面层3被适当地设定大小，以抵靠定位引导件4安置在基板上。
如图3和图4B中所示，然后根据要求定向LVT表面层3并将其放置在基板2上，并在定位引导件4内对准，使得LVT表面层3的背面安置在基板2的顶表面5上。如图4C中所示，然后将压力施加到基板2上的LVT表面层3，诸如通过操作轧辊机M，使得LVT表面层3粘合到基板2以形成超大的坯料10。然后，将坯料10平坦堆叠在冷却架(未示出)上另外24小时。
然后，将超大的坯料10传送到压模(未示出)的表面上。操作者为冲头(未示出)提供动力，并且锥形冲头切割脊的平坦表面接触超大的坯料10的边缘并剪掉超大的部分，从而留下符合尺寸要求的互锁瓷砖。冲头的动作将精确大小的瓷砖压入压模的空腔中，到达冲孔瓷砖支撑随后位于压模上的超大的坯料10的位置。有利地，压模具有开口底部，当上覆的超大坯料10被冲孔时，已经冲孔的瓷砖落到移除传送带上。
应当理解，本发明不限于本文描述的仅作为示例给出的具体细节，并且在不脱离如所附权利要求书中限定的本发明范围的情况下，可能够做出各种修改和改变。

Claims (12)

1.一种生产用于模块化地板***的互连多层豪华乙烯基地板瓷砖(LVT)的方法，所述方法包括以下步骤：
a)通过注射成型形成具有至少一个定位引导件的塑料材料基板；
b)用粘合剂涂覆LVT表面层的背面；
c)将所述LVT表面层与所述基板的顶表面对准，使得所述LVT表面层邻接所述基板的所述定位引导件或每个定位引导件；
d)将所述基板和所述LVT表面层一起压轧，以形成超大的坯料；以及
e)使用冲头和压模工具从所述超大的坯料中冲出互锁形状。
2.如权利要求1所述的方法，其中所述定位引导件是在所述基板的顶表面的周边的一部分处的直立区段。
3.如权利要求2所述的方法，其中所述定位引导件是在所述基板的顶表面的一个或多个转角处的直立区段。
4.如权利要求1所述的方法，其中所述定位引导件是坚固的直立墙。
5.如权利要求1所述的方法，其中所述基板是四边的。
6.如权利要求5所述的方法，其中所述基板在两个相邻的转角处具有定位引导件。
7.如权利要求1至6中任一项所述的方法，其中步骤(a)中的所述塑料材料是热塑性弹性体。
8.如权利要求1至6中任一项所述的方法，其中在步骤b)中使用的所述粘合剂是热熔聚氨酯粘合剂。
9.如权利要求1至6中任一项所述的方法，其中在步骤b)中使用辊涂机将所述粘合剂施加到所述LVT表面层。
10.如权利要求1至6中任一项所述的方法，其中使用轧辊机实现步骤d)中的所述压轧。
11.如权利要求1至6中任一项所述的方法，其中所述互锁形状包括在所述基板的相邻侧处的多个突出的舌片和凹口。
12.如权利要求1至6中任一项所述的方法，其中所述基板的厚度在3mm至8mm的范围内。
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