High-end Anti-slip Light Wood Grain Vinyl Floor Covering Rolls for Public Transportation

Short Description:

Emery PVC flooring is a composite flooring that combines PVC (polyvinyl chloride) elastic flooring with an emery (silicon carbide) wear-resistant layer. It offers exceptional wear resistance, anti-slip properties, and corrosion resistance, making it commonly used in high-use areas such as factories, hospitals, and schools. The following is its production method and key processes:
I. Basic Structure of Emery PVC Flooring
1. Wear-Resistant Layer: UV Coating + Emery Particles (Silicon Carbide).
2. Decorative Layer: PVC Wood Grain/Stone Grain Printed Film.
3. Base Layer: PVC Foam Layer (or Dense Substrate).
4. Bottom Layer: Glass Fiber Reinforcement Layer or Cork Soundproofing Pad (Optional).
II. Core Production Process
1. Raw Material Preparation
- PVC Resin Powder: Main Raw Material, Provides Elasticity and Formability.
- Plasticizer (DOP/DOA): Increases Flexibility.
- Stabilizer (Calcium Zinc/Lead Salt): Prevents High-Temperature Decomposition (Calcium Zinc is recommended for environmentally friendly options).
- Silicon carbide (SiC): Particle size 80-200 mesh, mixed in appropriate proportions (typically 5%-15% of the wear-resistant layer).
- Pigments/Additives: Antioxidants, flame retardants, etc.

2. Wear-Resistant Layer Preparation
- Process:

1. Mix PVC resin, plasticizer, silicon carbide, and UV resin into a slurry.

2. Form a film through doctor blade coating or calendaring, and UV cure to form a high-hardness surface layer.
- Key Points:
- Silicon carbide must be evenly dispersed to avoid clumping that affects surface smoothness.
- UV curing requires controlled UV intensity and duration (typically 3-5 seconds).

3. Decorative Layer Printing
- Method:
- Use gravure printing technology to print wood/stone grain patterns onto the PVC film.
- Some high-end products utilize 3D simultaneous embossing technology to achieve a matching texture.
4. Substrate Forming
- Compact PVC Substrate:
- PVC powder, calcium carbonate filler, and plasticizer are mixed in an internal mixer and calendered into sheets.
- Foamed PVC Substrate:
- A foaming agent (such as AC foaming agent) is added, and foaming is carried out at high temperature to form a porous structure, improving the foot feel.

5. Lamination Process
- Hot Press Lamination:

1. The wear-resistant layer, decorative layer, and substrate layer are stacked in sequence.

2. The layers are pressed together under high temperature (160-180°C) and high pressure (10-15 MPa).

- Cooling and Shaping:
- The sheet is cooled by cold water rollers and cut into standard sizes (e.g., 1.8m x 20m rolls or 600x600mm sheets).

6. Surface Treatment
- UV Coating: A secondary application of UV varnish enhances gloss and stain resistance.

- Antibacterial Treatment: A medical-grade silver ion coating is added.
III. Key Quality Control Points
1. Abrasion Resistance: The abrasion resistance level is determined by the carborundum content and particle size (must pass EN 660-2 testing).
2. Slip Resistance: The surface texture design must meet R10 or higher slip resistance standards.
3. Environmental Protection: Testing for limits for phthalates (6P) and heavy metals (REACH).
4. Dimensional Stability: The glass fiber layer reduces thermal expansion and contraction (shrinkage ≤ 0.3%).
IV. Equipment and Cost
- Main Equipment: Internal Mixer, Calender, Gravure Printing Press, UV Curing Machine, Hot Press.
V. Application Scenarios
- Industrial: Warehouses and Workshops (forklift resistance).
- Medical: Operating Rooms and Laboratories (antibacterial requirements).
- Commercial: Supermarkets and Gyms (high-traffic areas with anti-slip properties).
For further formulation optimization (e.g., to improve elasticity or reduce costs), the plasticizer ratio can be adjusted or recycled PVC can be added (paying attention to the performance balance).