Co-extrusion SPC foam flooring and manufacturing method thereof
AssigneeUnilin BV
InventorsJiangang Song, Jiajin Fu, Fuqing Liu
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Abstract
A foam flooring includes a stone-plastic base material structure, which sequentially comprises, from top to bottom, a first stable layer, a foaming layer and a second stable layer. The first stable layer and the second stable layer are both sheets with a PVC resin and filler powder as main components, with 25-40 parts by mass of the PVC resin and 55-75 parts by mass of the filler powder; and the density of the SPC foam flooring is 1.4-1.6 g/cm3. The foaming layer is arranged between the two stable layers, such that the overall density of the flooring is significantly reduced and reaches 1.4-1.6 g/m3; since the foaming layer is arranged inside, the surface strength of the overall flooring is not influenced.
Claims11
A flooring, comprising a base material structure, and a decorative and protective structure;
- wherein said decorative and protective structure sequentially comprises, from top to bottom, a UV coating, a wear-resistant layer, and a decorative layer, wherein said wear-resistant layer comprises a polyvinylchloride (PVC) resin and a plasticizer with said PVC resin being a main component, and wherein said decorative layer is a PVC film with a surface pattern;
- wherein said base material structure sequentially comprises, from top to bottom, a first stable layer, and a foaming layer, and a second stable layer;
- wherein said decorative layer is laminated to the first stable layer;
- and
- wherein said the first stable layer is a sheet with a PVC resin and filler powder as main components, wherein the first stable layer comprises 100 parts by weight of the PVC resin and at least 250 parts by weight of the filler powder;
- wherein said foaming layer is a chemical foaming layer comprising 100 parts by weight of PVC resin and at least 150 parts by weight of filler powder;
- wherein the second stable layer is a sheet with a PVC resin and filler powder as main components, wherein the second stable layer comprises 100 parts by weight of the PVC resin and at least 250 parts by weight of the filler powder;
- wherein the thickness of the foaming layer is in the range of 2 to 10 mm;
- and
- wherein said flooring has a density in the range of 1.4 to 1.6 g/cm3.
A flooring, comprising a base material structure, and a decorative and a protective structure;
- wherein said decorative and protective structure sequentially comprises, from top to bottom, a UV coating, a wear-resistant layer, and a decorative layer, wherein said wear-resistant layer has a thickness of 0.1 to 1 millimeter and comprises PVC resin and plasticizer with said PVC resin being a main component, and wherein said decorative layer is a PVC film with a surface pattern;
- wherein said base material structure sequentially comprises, from top to bottom, a first stable layer, and a foaming layer, and a second stable layer wherein said the first and second stable layers are is coextruded with said foaming layer, and wherein said decorative layer is laminated to said the first stable layer, and
- wherein said the first stable layer is a sheet with a PVC resin and filler powder as main components, wherein the stable layer comprises 100 parts by weight of the PVC resin and at least 250 parts by weight of the filler powder;
- wherein said foaming layer is a chemical foaming layer comprising 100 parts by weight of PVC resin and at least 150 parts by weight of filler powder, wherein the thickness of said foaming layer is in the range of 2 to 10 mm;
- wherein the second stable layer is a sheet with a PVC resin and filler powder as main components, wherein the second stable layer comprises 100 parts by weight of the PVC resin and at least 250 parts by weight of the filler powder;
- wherein the thickness of said the first stable layer is lower than said thickness of said foaming layer, wherein said filler powder is or comprises calcium carbonate and said flooring having a density in the range of 1.4 to 1.6 g/cm3.
Dependencies are inferred from the claim text.