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.

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° 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˜250° C., the time is controlled within 3˜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.