In today's construction and home decoration fields, wood-plastic flooring is gradually becoming more widely used due to its environmental protection characteristics and good performance. The extrusion molding process is undoubtedly the core link that determines the quality of wood-plastic flooring products. To optimize this process, we need to comprehensively and in-depth promote it from multiple key aspects.
1. Raw material screening and preprocessing
High-quality wood powder and plastic form the basic elements of high-quality wood-plastic flooring. When the fiber length of wood powder is accurately controlled in the range of 0.2 - 0.5 mm and its particle size is less than 80 mesh, a large amount of experimental data has confirmed that its mixing effect with plastic can be significantly improved by about 30%. At the same time, the moisture content of wood powder must be strictly controlled below 5%. Only in this way can its compatibility and fluidity with plastic during the mixing process be effectively enhanced, so that the two can be fully integrated. For plastic raw materials, whether virgin plastics or recycled plastics, the impurity content should be limited to less than 1% to ensure the stability of the entire raw material system. Before officially entering the extrusion molding process, a series of pre-treatment operations are carried out on the raw materials, such as drying and dehydration to remove excess water, and fine grinding to make the wood powder texture more delicate and uniform. This is to lay a solid foundation for subsequent smooth extrusion molding. Basic key steps.
2. Extruder selection and adjustment
The selection of the extruder needs to be determined closely based on the actual production scale and the specific specifications of the wood plastic flooring. Usually, large enterprises often use twin-screw extruders with screw diameters in the range of 90 - 120 mm in their production processes. This type of extruder can show good performance when processing larger volumes of materials. . In order to ensure that the material can pass through the mold smoothly and stably and be formed, the extrusion pressure should reach the range of 15 - 25MPa. The reasonable setting of the screw speed cannot be ignored. It is generally suitable to control it at 20-35 rpm. This speed can effectively ensure that the materials are evenly mixed in the extruder and maintain a stable conveying state. Throughout the extrusion process, temperature control is a top priority. Once the temperature is too low, for example, below 160°C, the plasticization process of the material will be difficult to fully complete, resulting in a rough texture on the surface of the wood-plastic floor, and its strength will be greatly reduced; conversely, if the temperature is too high, If the temperature exceeds 220°C, the material will easily decompose, resulting in color differences, bubbles and other defects that seriously affect product quality. Only through careful design and maintenance of appropriate temperature distribution can wood powder and plastic reach the ideal plasticization state at each stage of extrusion. It can also help reduce energy consumption by about 20% and achieve production efficiency and cost. Double optimization of control.
3. Mold design and optimization
The mold plays the role of "shaping artifact" in the extrusion molding process of wood plastic flooring. The rationality of its structural design directly determines whether the material can flow evenly and smoothly during extrusion. When the temperature of the mold is accurately controlled in the range of 180 - 200°C and the pressure is maintained in the range of 8 - 12MPa, the wood plastic flooring can show a regular shape after molding, and its dimensional accuracy deviation can be effectively controlled within Within ±0.5 mm, which is extremely important to ensure product quality consistency and installation suitability.
4. Optimization of process parameters
The optimization of process parameters is inseparable from a large number of rigorous experiments and in-depth and detailed data analysis. For example, after more than 50 tests of different parameter combinations, a company found that when the extrusion temperature is stabilized at 190-210°C, the pressure is controlled at 18-22MPa, and the extrusion speed is maintained at 1.5-2.5 meters/minute, the specific conditions Under this condition, the flexural strength of wood-plastic flooring can be significantly improved by about 25%, and the aging time of weather resistance can also be extended by about 30%. These precise parameter combinations provide reliable basis and guidance for maximizing the performance of wood-plastic flooring during the actual production process.
5. Quality control and testing
In the quality control and testing process, relevant data shows that using a laser displacement sensor with an accuracy of 0.01 mm to monitor the thickness of wood-plastic flooring in real time can control the thickness deviation within ±0.1 mm, effectively ensuring the dimensional accuracy of the product. Detecting product color through a colorimeter can ensure that the color difference value ΔE is less than 1.5, making the product color consistent. In addition, each batch of products is sampled for tensile strength testing, and the sampling ratio is not less than 5%. If the tensile strength is found to be lower than 95% of the standard value, the entire batch of products will be retested and adjusted. Strictly control product quality to ensure that products meet relevant standards and provide consumers with reliable products.
6. Equipment maintenance and upkeep
Regular comprehensive and meticulous maintenance and upkeep of core production equipment such as extruders and molds is an important guarantee for maintaining the continuous and stable operation of the production process. Generally speaking, after every 500-800 tons of wood plastic flooring is produced, the screw and barrel of the extruder should be comprehensively inspected and maintained. According to statistics, equipment that undergoes such regular maintenance can reduce its failure rate by about 30%. During the inspection, if it is found that the wear of the screw exceeds 0.5 mm or the wear depth of the inner wall of the barrel reaches 0.3 mm, the corresponding parts need to be replaced in time. At the same time, cleaning the residual materials inside the equipment during each maintenance can increase the production efficiency of the equipment by about 10%, ensuring that the equipment is always in the best operating condition and maintaining its high-precision performance for a long time, which provides high efficiency and high efficiency for wood-plastic flooring. Stable production is guaranteed.
7. R&D and Innovation
Scientific and technological development and market demand promote the progress of wood-plastic flooring technology. Pay attention to new technologies, etc., and explore new plastic additives and mold manufacturing processes, which can improve performance, precision and lifespan. The introduction of new elements can enhance competitiveness, meet diverse needs, and help the development of wood-plastic flooring in the field of environmentally friendly building materials.
To sum up, optimizing the extrusion molding process of wood-plastic flooring is a comprehensive and wide-ranging system project. It requires a comprehensive consideration of the above-mentioned key factors, and persistently conducts a large number of experiments, continuous improvement and innovation. Only in this way can we stably produce high-quality, high-performance wood-plastic flooring products to meet the strong demand for high-quality wood-plastic flooring in the construction and home decoration markets.
