Non-pvc wood-plastic panel with three-dimensional wood grain and preparation method and application thereof

Abstract

The present application relates to the technical field of floor manufacturing, and particularly relates to a non-polyvinyl chloride wood-plastic plate with three-dimensional wood grain and a preparation method and application thereof. The non-polyvinyl chloride wood-plastic plate comprises a non-polyvinyl chloride wood-plastic base layer containing polyolefin resin with surface energy not higher than 35 dynes / cm, and an adhesive bottom attached to one side of the non-polyvinyl chloride wood-plastic base layer and having surface tension less than that of the polyolefin resin. The non-polyvinyl chloride wood-plastic plate further comprises a two-dimensional pattern layer, a three-dimensional wear-resistant layer and a top paint layer. The present application limits the surface energy relationship between the adhesive bottom and the non-polyvinyl chloride wood-plastic base layer, thereby effectively preventing the non-polyvinyl chloride wood-plastic plate from peeling, warping and cracking, and effectively improving the stability and durability of the plate. Meanwhile, the prepared non-polyvinyl chloride wood-plastic plate can realize the environmental protection production and recycling of wood-plastic plates, and the visual and tactile three-dimensional wood grain is closer to the real wood grain.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of floor manufacturing, in particular to a non-polyvinyl chloride wood-plastic floor panel with three-dimensional wood grain and a preparation method and application thereof. BACKGROUND

[0002] As an important part of the building material industry, the floor industry has witnessed the continuous evolution and transformation of various types of floors as people's pursuit of quality of life continues to grow. From traditional solid wood floors to modern composite floors, to today's new three-dimensional floors, the floor industry has witnessed the continuous evolution and transformation of various types of floors. Looking to the future, with the increasing demand for building decoration and the accelerated urbanization process, the floor industry has a promising future.

[0003] Among them, three-dimensional floor is a uniquely designed floor that uses visual effects and material combinations to give it a three-dimensional and depth. This type of floor usually creates a three-dimensional visual effect through the clever combination of different materials, colors and textures, as well as unique pattern designs, giving people a more spacious and rich spatial experience.

[0004] Currently, with the increasing demand for interior decoration and design, the demand for personalized, fashionable and artistic decorative materials is growing. As a decorative material with unique visual effects and artistic sense, three-dimensional floor is becoming increasingly popular with more and more consumers. At the same time, with the rapid development of technology, the manufacturing process of three-dimensional floor will continue to improve, and material selection and design innovation will further enhance the market competitiveness of three-dimensional floor. It can be predicted that three-dimensional floor will continue to be concerned and favored in the market in the future.

[0005] Polyvinyl chloride (PVC) material has a wide range of applications in three-dimensional floor due to its good durability, excellent water resistance and easy cleaning and maintenance.

[0006] For example, the patent with the authorization announcement number CN112095967B discloses a multi-layer synchronous registration die pressing round edge PVC panel, which includes a UV paint layer, a PVC wear-resistant layer, a PVC pattern film layer, a PVC base plate and a PVC bottom material layer. The panel surface has a synchronous registration simulation three-dimensional texture, and the four corners have a circular arc edge and a lock structure, realizing the mutual lock and splice of the panels.

[0007] In addition, the patent with the publication number CN114953665A discloses a preparation process of PVC floor, which stacks a PVC base plate layer, a PVC printing layer and a PVC pre-coating film, and performs one-time lamination treatment to obtain a PVC floor product.

[0008] However, as PVC flooring is widely used, its inherent defects gradually emerge:

[0009] Firstly, although PVC materials have strong stability and durability, they also pose difficulties in recycling. Additionally, due to the need for special treatment methods during the recycling process, the recycled materials may not be easily reused, which reduces the resource recovery rate of PVC artificial flooring and leads to resource waste.

[0010] Secondly, during production, use, and disposal, PVC artificial flooring may release harmful substances such as volatile organic compounds (VOCs). These volatile organic compounds pose potential risks to the environment and human health, particularly in indoor environments, which may lead to decreased air quality and potentially trigger allergic reactions or respiratory diseases.

[0011] Furthermore, due to the poor heat resistance of PVC materials, prolonged exposure to high-temperature environments may cause softening deformation or even release of harmful gases. This limits the application of PVC artificial flooring in certain special environments, such as near stoves or in places exposed to sunlight.

[0012] Finally, the production process of PVC artificial flooring may generate large amounts of harmful waste gas and wastewater, negatively impacting the environment. Its characteristics of being unsuitable for sustainable development have gradually attracted attention, promoting the development and application of green and environmentally friendly materials.

[0013] Therefore, technicians are seeking alternative materials to address these issues, including wood-plastic composite flooring made from polyolefin materials (such as polypropylene, polyethylene, etc.) or polyester materials (such as PET, PETG, PBT, etc.). These new materials have better environmental friendliness and durability, and are expected to become the development trend of the flooring industry in the future.

[0014] For example, the patent with publication number CN117511148A provides a NON-PVC plastic flooring and its manufacturing process, which uses PET-P, PET-G, or PP resin, calcium powder, various lubricants, processing aids, etc. to mix and synthesize, then granulates through a specially designed extruder, and then uses an extruder for secondary extrusion processing to produce NONPVC-LVT flooring and NONPVC-SPC flooring products. The LVT flooring and SPC flooring made from PET-P, PET-G, or PP resin instead of the originally considered toxic PVC have better comprehensive physical indicators, performance, and service life than the replaced products.

[0015] In addition, the patent with publication number CN109944411A discloses a PET plastic floor, which at least includes a substrate layer and a printing layer arranged on the substrate layer. The substrate layer is made of PET or a mixture of PET and PE material or a mixture of PET and PP material. The printing layer is formed by spraying patterns on the substrate layer in a digital spraying manner or by adhering the printing layer to the upper surface of the substrate layer. A protective layer is further arranged on the printing layer. The PET plastic floor does not contain halogen and will not produce dioxin when burning, which helps to reduce air pollution. The invention can use new PET or recycled PET, and then combine with PE, PP and other high molecular thermoplastic materials to form the substrate layer. Then, according to the required properties, the printing layer and wear-resistant layer are compounded on the substrate layer to form an environmentally friendly and recyclable plastic floor. The PET plastic floor can be recycled to form renewable resources for recycling.

[0016] However, the applicant of the present application found that when using polyolefin materials to prepare three-dimensional floor, the adhesion between the substrate and the three-dimensional surface layer is weak, which easily leads to delamination, warping and cracking problems. This situation has not been observed in traditional PVC substrates. The applicant has tried to use the adhesion materials used in PVC substrates to enhance the adhesion between the polyolefin substrate and the three-dimensional layer, but the result is not satisfactory.

[0017] Therefore, based on the above-mentioned defects, the non-polyvinyl chloride wood-plastic board prepared by using polyolefin materials encounters certain obstacles in the production of three-dimensional floor. In order to overcome these problems, a series of targeted optimization and improvement of the three-dimensional floor prepared by using polyolefin materials and its preparation process are needed to improve the quality, stability and environmental protection of the non-polyvinyl chloride wood-plastic board. Through innovation and technological progress, more choices are brought to the floor industry, and the whole industry is promoted to a more sustainable and environmentally friendly direction. SUMMARY

[0018] The present application is to overcome the defects in the prior art that the adhesion between the substrate and the three-dimensional layer of the non-polyvinyl chloride wood-plastic board is weak, which leads to low stability of the non-polyvinyl chloride wood-plastic board. Therefore, a new type of non-polyvinyl chloride wood-plastic board with three-dimensional wood grain and its preparation method and application are provided to overcome the above-mentioned deficiencies.

[0019] To achieve the above-mentioned application purposes, the present application realizes the following technical solutions:

[0020] In the first aspect, the present application first provides a non-polyvinyl chloride wood-plastic board with three-dimensional wood grain, which comprises:

[0021] a non-polyvinyl chloride wood-plastic substrate layer, which comprises a polyolefin resin with a surface energy not higher than 35 mN / m;

[0022] an adhesive primer on one side of the non-polyvinyl chloride wood-plastic substrate layer; wherein,

[0023] the surface tension of the adhesive primer is less than the surface tension of the polyolefin-based resin, and the difference between the surface tension of the adhesive primer and the surface tension of the polyolefin-based resin is less than 5 mN / m;

[0024] a two-dimensional pattern layer attached to the adhesive primer away from the non-polyvinyl chloride wood-plastic substrate layer; wherein,

[0025] the two-dimensional pattern layer comprises a plurality of connected or unconnected two-dimensional wood grain lines obtained by digital printing;

[0026] a three-dimensional wear-resistant layer above the two-dimensional pattern layer, the three-dimensional wear-resistant layer comprising a three-dimensional base layer covering the entire two-dimensional pattern layer and a three-dimensional wear-resistant layer comprising at least a portion or all of the protrusions or grooves corresponding to the two-dimensional wood grain lines or the gaps between the two-dimensional wood grain lines in the two-dimensional pattern layer;

[0027] a surface paint layer on the surface of the three-dimensional wear-resistant layer, at least a portion of the surface paint layer being lower than the upper surface of the three-dimensional wear-resistant layer.

[0028] The present application uses a non-polyvinyl chloride wood-plastic board as a substrate layer, combines digital printing technology and three-dimensional layer design, and realizes the environmentally friendly production and recycling of wood-plastic boards. This structural design not only reduces the consumption of traditional wood, promotes resource conservation and recycling, but also meets the requirements of modern society for environmental protection and sustainable development, and has good social benefits and market prospects.

[0029] Specifically, the non-polyvinyl chloride wood-plastic board with three-dimensional wood grain in the present application is endowed with a unique three-dimensional wood grain appearance by the wood grain lines obtained by digital printing in the two-dimensional pattern layer and the design of the three-dimensional base layer and the protrusions / grooves of the three-dimensional wear-resistant layer, so that the non-polyvinyl chloride wood-plastic board creates a simulated wood texture and improves the visual effect and artistic sense of the product.

[0030] In order to enhance the bonding stability between the substrate and the adhesive layer, methods such as corona treatment are usually used to increase the surface energy of the substrate, thereby enhancing the bonding strength between the substrate and other layer structures. However, the present inventors have found that after the substrate is treated by means such as corona treatment, the surface energy of the substrate will indeed increase for a period of time, but this effect will decrease over time, so that the use of such technical means can only maintain a relatively short period of time. In addition, if the surface energy of the substrate is excessively increased by means such as corona treatment, the bonding stability between the substrate and the adhesive primer may even decrease. Therefore, the existing technology is difficult to achieve long-term and stable improvement of the bonding stability between the substrate and the adhesive primer.

[0031] For the flooring industry, the design service life of the floor is usually several years or even decades, and it is often subjected to external mechanical impact (such as the movement of pedestrians, the falling and accumulation of heavy objects, etc.) and environmental climate tests (such as light, cold and heat, wind and rain, bacteria, etc.) during the design service life. Due to the multi-layer structure of the three-dimensional floor, the above tests will cause irreversible damage (such as delamination, cracking, warping, etc.) to the three-dimensional floor with a multi-layer structure. In addition, these challenges are even more severe for three-dimensional floors suitable for outdoor use. Therefore, some existing ways to improve the bonding stability between the substrate and the attached bottom often cannot be used for a long time.

[0032] Furthermore, the non-polyvinyl chloride wood-plastic panel with three-dimensional wood grain described in the present application as a new type of floor material represents a new trend in the development of the flooring industry, replacing traditional polyvinyl chloride wood-plastic panels. However, the current industry still has limited research on non-polyvinyl chloride wood-plastic panels themselves, and their physical and chemical properties are not yet clear. Therefore, the method for improving the long-term bonding stability between the polyolefin-based resin and the attached bottom is still unclear, and it is necessary for researchers in the industry to continue to invest a lot of effort in further research.

[0033] The inventors of the present application found in the experimental process that although the surface energy of the substrate is an important parameter for characterizing the adhesion ability of the material surface, it has an important influence on the stability of the three-dimensional wood-plastic panel, but the inventors also found that there is a more significant relationship between the surface energy relationship between the two materials and the bonding strength between them.

[0034] Based on this discovery, the present application achieves the stability and reliability of the panel under use and environmental changes by controlling the surface energy difference between the non-polyvinyl chloride wood-plastic substrate layer and the attached bottom to be less than 5 mN / m in the design.

[0035] The reason is that an appropriate surface energy difference range can help balance the surface energy of the two materials, so that the non-polyvinyl chloride wood-plastic substrate layer and the attached bottom are better combined, maintaining a relatively stable state, which helps to prevent deformation and damage of the panel under different temperature and humidity environments. The inventors of the present application found in experiments that when the surface energy difference between the polyvinyl chloride wood-plastic substrate layer and the attached bottom is within the set range, the two are more firmly combined, effectively preventing peeling and improving the stability and durability of the panel.

[0036] As a preferred, the polyolefin-based resin is any one or a combination of polyethylene, polypropylene, polyisobutylene, ethylene-vinyl acetate copolymer, ethylene-polypropylene copolymer, ethylene-acrylic acid or acrylic ester copolymer, and poly-4-methyl-1-pentene.

[0037] As preferred, the adhesion of the non-polyvinyl chloride wood-plastic substrate layer to the adhesive bottom is rated 5B according to the method described in ASTM D3359.

[0038] As preferred, the non-polyvinyl chloride wood-plastic substrate layer further comprises fillers and processing aids.

[0039] As preferred, the fillers are wood powder and / or stone powder.

[0040] As preferred, the adhesive bottom is obtained by curing a photocurable resin composition;

[0041] The photocurable resin composition comprises a main resin with photosensitive groups attached;

[0042] The main resin further comprises hydrogen bond donor groups and hydrogen bond acceptor groups for forming hydrogen bonds.

[0043] The adhesive bottom in the present application is cured from a photocurable resin composition, which comprises a main resin with photosensitive groups, hydrogen bond donor groups and hydrogen bond acceptor groups for forming hydrogen bonds. The photosensitive groups have high sensitivity to light and can quickly respond to the irradiation of light sources, making the photocurable resin have the characteristics of rapid curing, forming a strong adhesive bottom, shortening the production cycle, and improving the production efficiency and throughput.

[0044] Moreover, due to the presence of hydrogen bond donor and acceptor groups in the photocurable resin composition, the interaction force between the main resin and the substrate layer can be enhanced through hydrogen bond formation. This unique structure forms stronger chemical bond during the curing process, improving the bonding strength and adhesion between the adhesive bottom and the substrate layer, ensuring the stability and durability of the wood-plastic panel structure.

[0045] In addition, the present application utilizes the combination of hydrogen bond donor and acceptor groups to make the adhesive bottom formed by the photocurable resin composition have more uniform and stable surface treatment quality. The formation of hydrogen bonds helps to reduce the tension of the material surface, reduce the unevenness of surface energy, enhance the consistency and flatness of surface treatment, and improve the processing stability and quality control ability in the panel production process.

[0046] Finally, the photocuring technology itself belongs to the green and environmentally friendly curing method, without adding solvents or other harmful substances, avoiding the emission of volatile organic compounds, meeting the requirements of environmental protection and sustainable development. This design realizes the green and environmentally friendly production process by curing the adhesive bottom with photocurable resin, and provides a sustainable solution for the material selection and production of wood-plastic panels.

[0047] As preferred, the photocurable resin composition has a dynamic viscosity of 80 seconds-250 seconds.

[0048] The dynamic viscosity of the photocurable resin composition is in the range of 80-250 seconds, which can meet the bonding and curing requirements within a proper time. The moderate dynamic viscosity enables the resin to have proper viscosity and fluidity during the coating and application process, ensuring uniform coating and complete coverage, and facilitating the firm bonding between the adhesive primer and the substrate layer and the curing effect. At the same time, the proper dynamic viscosity improves the operability and stability of the production process, making the resin more easily controllable and operable during the coating and curing process. The resin has moderate viscosity and viscosity, which can effectively adhere to the substrate surface without being too fluid or diluted, maintaining the stability and continuity of the production process and improving the efficiency and quality of product production.

[0049] As a preferred, the adhesive primer has a weight of 10 g / m 2 -15 g / m 2 .

[0050] In actual tests, the inventors found that the coating amount of the adhesive primer has a significant impact on the bonding strength of the substrate and the deformation control of the wood-plastic panel. When the coating amount of the adhesive primer is less than 10 g / m 2 , it is found that the bonding strength between the adhesive primer and the non-polyvinyl chloride wood-plastic substrate layer is low, which may cause problems such as delamination and cracking of the three-dimensional floor; and when the coating amount of the adhesive primer exceeds 15 g / m 2 , the shrinkage generated during the curing of the adhesive primer is too large, which may cause the three-dimensional floor to warp.

[0051] As a preferred, the main resin contains any one of amide group, imide group, amino group, carbamate group, hydroxyl group, and urea group.

[0052] As a preferred, the photocurable resin composition further contains an auxiliary resin having a photosensitive group and an active diluent;

[0053] At least one of the auxiliary resin and the active diluent contains a hydrogen bond acceptor group.

[0054] By adding the auxiliary resin and the active diluent containing the photosensitive group, especially the component containing the hydrogen bond acceptor group, the present application can improve the photosensitivity and reaction speed of the photocurable resin composition. Under light conditions, the photosensitive group absorbs light energy, prompting the resin to undergo a photocuring reaction, and the active component containing the hydrogen bond acceptor group accelerates the curing process, promotes the photoinitiated polymerization reaction, thereby improving the curing efficiency and shortening the curing time.

[0055] The hydrogen bond acceptor groups in the added auxiliary resin and active diluent improve the selectivity and controllability of the curing reaction of the photocuring resin composition. The hydrogen bond acceptor groups participate in the hydrogen bond interaction in the curing process, help to regulate the curing reaction speed and mechanism, improve the selectivity of the curing reaction, and make the curing process more controllable and stable. By precisely controlling the hydrogen bond interaction, adjusting the molecular structure and crosslinking degree of the photocuring resin, the hardness, wear resistance and chemical corrosion resistance of the product are improved, and the durability and stability are enhanced.

[0056] In addition, the auxiliary resin and active diluent containing hydrogen bond acceptor groups can also enhance the adhesion and weather resistance between materials. The hydrogen bond acceptor groups help to form a tighter bond with the surrounding matrix material, improve the adhesion of the cured resin to the substrate, and enhance the water resistance, temperature resistance and chemical corrosion resistance of the product, prolonging the service life of the product.

[0057] In summary, the present application introduces auxiliary resin and active diluent containing photosensitive groups, which contain at least one hydrogen bond acceptor group, which helps to improve the photocuring efficiency, improve the selectivity and controllability of the curing reaction, optimize the physical properties and durability, improve the surface quality and appearance of the product, and enhance the adhesion and weather resistance of the material, bringing more advantages and protection to the performance and application of the photocuring resin composition.

[0058] As a preferred, the addition amount of the main resin is 30wt%-40wt% of the total mass of the photocuring resin composition; and the addition amount of the auxiliary resin is not higher than 50wt% of the addition amount of the main resin.

[0059] The addition amount of the active diluent is not higher than 65wt% of the addition amount of the main resin.

[0060] The present application specifically limits the addition amount of the main resin, auxiliary resin and active diluent in the photocuring resin composition to ensure that the finally produced wood-plastic board has better anti-cracking and delamination effect.

[0061] The addition amount of the main resin is controlled between 30wt% and 40wt% of the total mass of the photocuring resin composition, which can ensure that the photocuring resin composition has enough curing main body and maintains chemical stability and curing effect. The main resin is a key component of the photocuring reaction, and appropriate control of the addition amount helps to maintain the balance and stability of the curing reaction, ensuring that the product has excellent physical and chemical properties after curing.

[0062] The addition amount of the auxiliary resin should not exceed 50wt% of the main resin, so as to adjust the formation of network structure and optimize the curing speed. The appropriate amount of auxiliary resin can support and stabilize the network structure during the curing process, promote the curing reaction, and avoid excessive addition leading to network structure disorder and excessive curing speed affecting the curing effect.

[0063] The addition amount of the active diluent should not exceed 65wt% of the main resin, which helps to control the balance between the curing volume and the coating performance. The appropriate amount of active diluent can adjust the curing volume and coating performance, improve the uniformity and curing efficiency of coating, and maintain the surface quality and consistency of the product.

[0064] Therefore, by reasonably setting the addition ratio of the main resin, auxiliary resin and active diluent, the process performance and stability of the photocuring resin composition can be optimized. The appropriate ratio can maintain the balance and coordination of the composition, improve the controllability and stability of the production process, and ensure that the product quality and performance meet the requirements.

[0065] Preferably, the addition amount of the auxiliary resin is not less than 25wt% of the main resin.

[0066] In this application, the addition amount of the auxiliary resin is set to be not less than 25wt% of the main resin, which can enhance the flexibility and toughness of the photocuring resin composition, and effectively adjust the balance between the curing volume and surface hardness. The appropriate amount of auxiliary resin helps to optimize the curing speed and degree of photocuring resin, avoids the curing system being too hard or too soft, and maintains the hardness and uniformity of the product surface. In addition, the appropriate amount of auxiliary resin can improve the flowability and ductility of the resin system during the curing process, so that the cured product has better elasticity and tensile resistance, and improves the wear resistance and impact resistance of the product.

[0067] At the same time, the appropriate amount of auxiliary resin can also improve the transparency and optical performance of the resin system. The composition of the auxiliary resin can optimize the refractive index and transparency of the cured layer, so that the light can penetrate the resin system more smoothly, improve the transparency and optical effect of the product, and make the wood grain clearer when digital wood grain printing is performed on the surface.

[0068] Preferably, the addition amount of the active diluent is not less than 40wt% of the main resin.

[0069] And the addition amount of the active diluent is set to be no less than 40wt% of the addition amount of the main resin, which can effectively adjust the viscosity and fluidity of the photocuring resin composition. The appropriate amount of active diluent helps to reduce the viscosity of the resin system, making it more flowable, improving the uniformity of coating and curing efficiency, while helping to avoid the phenomenon of bubbles or uneven coating, ensuring the surface quality of the product. In addition, the appropriate amount of active diluent can also speed up the curing speed of the resin system, shorten the curing time, improve the production efficiency, while ensuring the curing degree and quality of the product. Finally, the active diluent also helps to reduce the surface tension of the photocuring resin composition, reduce the generation of coating marks and defects, make the product surface more smooth and smooth, improve the gloss and transparency, thereby enhancing the surface gloss and transparency of the product.

[0070] As preferred, the photocuring resin composition further comprises a photoinitiator, a filler and an auxiliary agent.

[0071] As preferred, the addition amount of the photoinitiator is 3wt%-5wt% of the total mass of the photocuring resin composition;

[0072] The addition amount of the filler is 20wt%-30wt% of the total mass of the photocuring resin composition;

[0073] The addition amount of the auxiliary agent is 0.5wt%-1wt% of the total mass of the photocuring resin composition.

[0074] As preferred, the photoinitiator is a free radical photoinitiator.

[0075] As preferred, the active diluent contains at least two branched chains containing acrylic acid structure.

[0076] The branched chain containing acrylic acid structure in the active diluent of the present application can enhance the cross-linking property of the molecular chain of the active diluent. The presence of multiple acrylic acid structure chains can promote the formation of more cross-linking bonds between the active diluent molecules, thereby increasing the connection points of the molecular chain, and further improving the stability and durability of the molecular chain, which helps to improve the structural strength and anti-aging ability of the active diluent.

[0077] In addition, the polarity of the acrylic acid structure chain helps the compatibility of the active diluent with the resin matrix, which is conducive to the uniform dispersion of the active diluent in the resin system, enhances the stability and uniformity of the resin system, and improves the quality and performance of the product. At the same time, the softness and plasticity of the acrylic acid structure chain make the active diluent and the main resin form a closer combination, promote the interaction and chemical reaction between the two, reduce the interfacial tension, improve the interfacial bonding strength, make the resin more easily penetrate and cover the surface of the substrate, enhance the adhesion and adhesion, and ensure the firmness and durability of the curing layer.

[0078] As a preferred, the active diluent is any one of tripropylene glycol diacrylate (TPGDA), trimethylolpropane triacrylate (TMPTA), pentaerythritol triacrylate (PETA).

[0079] As a preferred, the filler is any one or a combination of more than one of silicon dioxide, calcium carbonate, aluminum oxide, titanium dioxide, magnesium oxide, talc powder, wollastonite powder, mica powder, precipitated barium sulfate, bentonite, calcium carbonate powder, ultra-fine aluminum silicate.

[0080] As a preferred, the adhesive base contains a color hiding agent for hiding the color of the non-polyvinyl chloride wood-plastic substrate layer; the two-dimensional pattern layer is printed on the surface of the adhesive base.

[0081] As another preferred, the surface of the adhesive base away from the non-polyvinyl chloride wood-plastic substrate layer is further covered with a color hiding film for hiding the color of the non-polyvinyl chloride wood-plastic substrate layer;

[0082] The two-dimensional pattern layer is printed on the surface of the color hiding film.

[0083] As another preferred, the surface of the adhesive base away from the non-polyvinyl chloride wood-plastic substrate layer is further covered with a color paint layer containing a color hiding agent;

[0084] The two-dimensional pattern layer is printed on the surface of the color paint layer.

[0085] In the present application, by adding a color hiding agent in the adhesive base or covering a color hiding film or color paint layer on the surface of the adhesive base away from the non-polyvinyl chloride wood-plastic substrate layer, the color of the non-polyvinyl chloride wood-plastic substrate itself can be hidden, providing more possibilities for subsequent customized design. At the same time, the clarity and protection of the pattern printed in the two-dimensional pattern layer can be enhanced, thereby helping the pattern printing to be more fine and clear, and prolonging the durability of the pattern.

[0086] In the present application, the printing of the two-dimensional pattern layer can realize the customization of the pattern, so that the wood-plastic board has a personalized appearance, meeting the different customer needs and design requirements. Through the cooperation of the color hiding agent, the color hiding film, the color paint layer and the surface printing of the two-dimensional pattern, the matching and coordinated overall effect between the layers of the product can be realized. The unity or contrast of color, pattern and texture makes the overall appearance of the wood-plastic board more layered and harmonious, improving the overall quality and visual effect of the product.

[0087] In a second aspect, the present application further provides a method for preparing the non-polyvinyl chloride wood-plastic board with three-dimensional wood grain as described above, comprising the following steps:

[0088] - providing a non-polyvinyl chloride wood-plastic substrate layer;

[0089] - coating a layer of photocuring resin composition on the surface of the non-polyvinyl chloride wood-plastic substrate layer, and curing the photocuring resin composition to obtain the adhesion primer, so that the difference in surface energy between the adhesion primer and the non-polyvinyl chloride wood-plastic substrate layer is less than 5 mN / m;

[0090] - printing on the surface of the adhesion primer to obtain a two-dimensional pattern layer;

[0091] - three-dimensional printing on the surface of the two-dimensional pattern layer to obtain a three-dimensional wear-resistant layer;

[0092] - coating a topcoat on the surface of the three-dimensional wear-resistant layer and curing to obtain the topcoat layer.

[0093] Preferably, the photocuring resin composition has a dynamic viscosity of 80 seconds to 250 seconds.

[0094] The photocuring resin composition has an application amount of 10 g / m 2 - 15 g / m 2 .

[0095] Preferably, the two-dimensional pattern layer is directly printed on the surface of the adhesion primer.

[0096] Preferably, the photocuring resin composition further comprises a color hiding agent for hiding the color of the non-polyvinyl chloride wood-plastic substrate layer.

[0097] Preferably, before printing the two-dimensional pattern layer, a step of coating a color paint on the surface of the adhesion primer and curing the color paint to form a color paint layer is further included, and the two-dimensional pattern layer is directly printed on the surface of the color paint layer.

[0098] Preferably, the color paint layer is white.

[0099] Preferably, the color paint is cured by photocuring.

[0100] The color paint at least comprises a photocrosslinking resin, a photoinitiator, and a white pigment powder.

[0101] Preferably, the color paint has a coverage of 15 g / m 2 - 20 g / m 2 .

[0102] Preferably, before printing the two-dimensional pattern layer, a step of adhering a color hiding film for hiding the color of the non-polyvinyl chloride wood-plastic substrate layer on the surface of the adhesion primer by heat is further included, and the two-dimensional pattern layer is directly printed on the surface of the color hiding film.

[0103] Preferably, the preparation steps of the three-dimensional wear-resistant layer comprise:

[0104] - a step of covering at least a part of the surface of the two-dimensional pattern layer with a resin liquid and curing the resin liquid to form a three-dimensional base layer; - a step of allowing at least a part of the surface of the three-dimensional base layer to be covered with at least one layer of resin liquid;

[0105] - a step of allowing at least a part of the surface of the resin liquid on the surface of the three-dimensional base layer to be applied with an embossing liquid along the wood grain pattern of the two-dimensional pattern layer, so that the embossing liquid and / or at least a part of the resin liquid mixed with the embossing liquid and / or at least a part of the resin liquid covered by the embossing liquid forms an embossed layer;

[0106] - a step of allowing the resin liquid other than the embossed layer formed in the previous step to be cured;

[0107] - a step of allowing the embossed layer to be removed, so as to form a three-dimensional wear-resistant layer on the surface of the three-dimensional base layer.

[0108] As a preference, the amount of resin liquid used to form the three-dimensional base layer is 30g / m 2 - 50g / m 2 .

[0109] As a preference, the amount of resin liquid covering the surface of the three-dimensional base layer is greater than or equal to 150g / m 2 , and at least a part of the surface of the three-dimensional base layer is covered with at least two layers of resin liquid.

[0110] Applicants have found in practical exploration that, in order to make the wood grain on the three-dimensional wear-resistant layer of the board surface closer to the feel of natural wood, it is necessary to control the coating amount of the resin liquid used to form the three-dimensional wood grain, and after testing, it is found that only when the total amount of resin liquid used for the three-dimensional base layer and the three-dimensional wood grain layer is greater than 200g / m 2 , can the texture formed thereby achieve a feel close to natural wood, while providing better wear resistance. However, when the resin liquid is coated at one time in an amount greater than 200g / m 2 , it is difficult for the bottom of the wear-resistant layer to be cured instantaneously, resulting in poor bonding force between the three-dimensional wear-resistant layer and the two-dimensional pattern layer on the board surface, and the three-dimensional wear-resistant layer is prone to peeling off from the substrate.

[0111] In order to achieve smooth curing of the resin liquid with large coating amount and improve the bonding force between the three-dimensional wear-resistant layer and the substrate, it is necessary to increase the curing power used during curing, but the provision of large power will generate more waste heat during the curing process, which will cause deformation of the board and yellowing or aging of the resin liquid, so this means of increasing the curing power is not practical.

[0112] After the applicant studies the solidified three-dimensional wear-resistant layer, it is found that the three-dimensional wear-resistant layer actually comprises two functional zones in the longitudinal direction, including: (1) a bonding zone for bonding with the non-polyvinyl chloride base material, i.e., the three-dimensional base layer in the present application; and (2) a functional zone for forming a three-dimensional structure, i.e., the three-dimensional wear-resistant layer in the present application. Among them, the three-dimensional base layer has a small user amount of resin, while the user amount of the three-dimensional wear-resistant layer needs to be 150 g / m 2 Only in this way can the approximate natural wood feel and better wear resistance be achieved.

[0113] Therefore, the present application coats the surface of the two-dimensional pattern layer with a first layer of resin liquid, and solidifies to obtain a three-dimensional base layer. Since the amount of resin liquid used to form the three-dimensional base layer is not large, it can be completely solidified under normal curing power, so that the bonding force between the three-dimensional base layer and the non-polyvinyl chloride wood-plastic base material layer containing the adhesive bottom can be effectively improved, and the peeling problem in the use process can be avoided. Subsequently, resin coating is performed on the surface of the three-dimensional base layer, and the resin coating amount is ensured to be 150 g / m 2 The above is used to form a three-dimensional wear-resistant layer, thereby ensuring the three-dimensional effect of the three-dimensional wood grain.

[0114] As a preferred, in the process of covering the surface of the three-dimensional base layer with any two adjacent layers of resin liquid, a transition treatment step of stopping the application of force to the resin liquid after the three-dimensional base layer is covered with any one layer of resin liquid is further included, and the covering of the next layer of resin liquid is performed after the transition treatment step is completed.

[0115] As described above, in order to ensure the three-dimensional effect of the three-dimensional wood grain, at least 150 g / m 2 of the above resin liquid needs to be coated on the surface of the three-dimensional base layer. Therefore, the focus of the present application is shifted to how to form a resin coating amount of 150 g / m 2 on the surface of the three-dimensional base layer.

[0116] At present, the most common way of applying resin liquid is to use a roll coater for coating. The applicant has tried to coat a resin liquid with a coating amount of 150 g / m 2 at a time on the three-dimensional base layer, but the applicant found that this one-time coating method needs to load too much resin liquid on a single roll. If a conventional roll is used to load too thick resin liquid, the resin liquid will flow down, thereby failing to complete normal production.

[0117] Therefore, in order to solve the above problems, two-roll distributed coating means are adopted in the present application, so that each roll coats a layer of resin liquid, thereby making the total amount of the two layers of resin liquid greater than 150 g / m 2The above is enough. This method realizes the coating of a large amount of resin and reduces the resin load pressure of each roller.

[0118] In the prior art, in order to realize the coating of multiple rollers, a roller coating machine with two parallel rollers is usually used. The two rollers of the roller coating machine usually adopt the combination of a positive roller and a reverse roller. In the process of coating the resin liquid on the surface of the plate and pushing the substrate forward, the first roller will generate a certain force on the plate and the resin liquid layer attached to the surface of the plate in the conveying direction of the plate. The force combined with the bristle structure on the surface of the roller will cause a certain deformation of the surface of the resin liquid. When the first layer of resin liquid has not yet been leveled, the second roller has already taken over the plate coated with the uncured resin liquid, and the second roller will generate a force opposite to the conveying direction of the plate on the uncured resin liquid. Therefore, the force will also cause the second layer of resin liquid to deform in the opposite direction. At the same time, due to the speed difference between the second roller and the first roller, the deformation between the first layer of resin liquid and the second layer of resin liquid cannot be offset, but instead, the deformation of the two layers of resin liquid is superimposed, further exacerbating the appearance of the resin liquid imprint. After curing, these imprints will be fixed, which seriously affects the visual effect of the final product. The appearance of these imprints will cause obvious defects in the appearance of the finished product, especially the finished product with shallow lines, that is, there is a pause in the middle of the part coated with resin liquid when viewed from a distance.

[0119] Therefore, based on the existing roller coating machine, a transition treatment step of stopping applying force to the resin liquid is added during the process of covering at least a part of the surface of the three-dimensional substrate layer with any two adjacent layers of resin liquid. In this way, during the process of passing through the first roller, the first roller stops applying force to the entire plate after the end of the force application, and then the plate is conveyed to the second roller without any force being applied to the entire plate. Then, after a long distance, the first layer of resin liquid is leveled, and then the plate is coated by the second roller from the beginning to the end. At this time, due to the small deformation of the second layer of resin liquid, the second layer of resin liquid can be quickly leveled before curing, thereby eliminating the influence of the force and speed difference of the two rollers on the surface morphology of the resin liquid.

[0120] Preferably, during the process of covering at least a part of the surface of the three-dimensional substrate layer with any two adjacent layers of resin liquid, the force application directions of the two adjacent layers of resin liquid are opposite.

[0121] As can be known from the above description, the roller coater will generate a certain force on the resin liquid during the roller coating. Since the resin liquid usually contains high molecular polymers or prepolymers, the molecular chain segments are relatively long, and thus the resin liquid will generate a certain elastic deformation and orientation force under the action of external force. Since the overall process time from coating to curing of the resin liquid is relatively short, the molecular chain segments of the high molecular polymers in the resin liquid have not returned to the initial state before the resin liquid is cured, resulting in that a relatively large internal stress is generated in the middle part of the cured three-dimensional wood grain layer, and thus the middle part of the cured three-dimensional wood grain layer is prone to cracking. Therefore, in order to reduce the generation of internal stress in the middle part of the three-dimensional wood grain layer, the application specifically adjusts the force direction of the two rollers on the adjacent resin liquid to be opposite in the process of covering the surface of at least part of the three-dimensional base layer with the adjacent resin liquid, so that the unhardened second wear-resistant layer can be provided with a force opposite to the internal stress in the second wear-resistant layer during the working process of the second roller, thereby weakening or offsetting the original internal stress of the three-dimensional wood grain layer, and thus the probability of cracking in the middle part of the cured three-dimensional wood grain layer can be reduced.

[0122] Preferably, the embossing liquid is applied to the surface of the resin liquid and / or penetrates into the interior of the resin liquid.

[0123] In the present application, the principle of forming the embossing layer by adding the embossing liquid to the surface of the resin liquid has various forms, including but not limited to ultraviolet covering method, free radical absorption method or volume occupation method.

[0124] The ultraviolet covering method is suitable for UV-cured resin liquid, and the principle is to cover the surface of the unhardened resin liquid with an embossing liquid capable of preventing ultraviolet light from penetrating, so that the resin liquid located below the embossing liquid can remain in a liquid state without curing, and thus the part of the resin liquid that does not cure forms an embossing layer, which is removed by mechanical cleaning or solution washing in the subsequent process, thereby obtaining a three-dimensional wood grain layer with a wood grain structure.

[0125] The free radical absorption method is suitable for resin liquid based on the principle of free radical polymerization, and the principle is to add the embossing liquid to the surface of the unhardened resin liquid or penetrate into the interior of the unhardened resin liquid, so as to absorb the free radicals used for the free radical polymerization of the resin liquid, so that the part of the resin liquid containing the embossing liquid can remain in a liquid state without curing, and thus the part of the resin liquid that does not cure forms an embossing layer, which is removed by mechanical cleaning or solution washing in the subsequent process, thereby obtaining a three-dimensional wood grain layer with a wood grain structure.

[0126] The volume occupation law refers to that when the embossing liquid penetrates into the un-solidified resin liquid, the un-solidified resin liquid is pushed away, and the part of the volume occupied by the embossing liquid only contains the embossing liquid which can be polymerizable or non-polymerizable. Finally, the embossing liquid is removed by mechanical or solvent cleaning, so as to obtain a three-dimensional wood grain layer with wood grain structure.

[0127] Preferably, the embossing liquid at least contains a polymerization inhibitor for preventing the polymerization of the light-crosslinking resin.

[0128] In the preferred embodiment, the polymerization inhibitor is added to the embossing liquid, which can quench the free radicals generated by the photoinitiator under light irradiation, thereby effectively preventing the polymerization of the resin liquid containing the polymerization inhibitor or reducing the curing speed of the resin liquid containing the polymerization inhibitor, so that the resin liquid containing the polymerization inhibitor can still remain in a liquid or semi-solid state, thereby making the embossed layer easier to be removed.

[0129] Preferably, the coverage of the topcoat is 20g / m 2 -30g / m 2 .

[0130] In a third aspect, the application also provides the use of the non-polyvinyl chloride wood-plastic board with three-dimensional wood grain as described above in floor panels, wall panels or ceiling panels.

[0131] Therefore, the application has the following beneficial effects:

[0132] (1) The application can effectively prevent the non-polyvinyl chloride wood-plastic board from peeling, warping and cracking by limiting the surface energy relationship between the adhesive bottom and the non-polyvinyl chloride wood-plastic base layer, thereby effectively improving the stability and durability of the board;

[0133] (2) The non-polyvinyl chloride wood-plastic board has a three-dimensional wood grain that is closer to the visual and tactile three-dimensional wood grain of real wood, thereby meeting the demand for pursuing a more realistic visual and tactile combination;

[0134] (3) The application uses a non-polyvinyl chloride wood-plastic board as a base layer, which can realize the environmentally friendly production and recycling of wood-plastic boards, thereby reducing the consumption of traditional wood, promoting resource conservation and recycling, and meeting the requirements of modern society for environmental protection and sustainable development, and having good social benefits and market prospects. BRIEF DESCRIPTION OF DRAWINGS

[0135] Figure 1 The schematic diagram of steps (S.1) to (S.2) for preparing the non-polyvinyl chloride wood-plastic board with three-dimensional wood grain in Example 1 of the application is shown in the figure.

[0136] Figure 2 The chart of the grid test results of the non-polyvinyl chloride wood-plastic board in the embodiment 1 of the present application and the attached bottom material in the scheme 1.

[0137] Figure 3 The chart of the grid test results of the non-polyvinyl chloride wood-plastic board in the embodiment 1 of the present application and the attached bottom material in the comparative scheme 2 (left) and the comparative scheme 4 (right).

[0138] Figure 4 The chart of the grid test results of the polyvinyl chloride wood-plastic board in the embodiment 1 of the present application and the attached bottom material in the scheme 1.

[0139] Figure 5 The schematic representation chart of the steps (S.3) - (S.4) for preparing the non-polyvinyl chloride wood-plastic board with three-dimensional wood grain in the embodiment 1 of the present application.

[0140] Figure 6 The schematic representation chart of the steps (S.5) - (S.8) for preparing the non-polyvinyl chloride wood-plastic board with three-dimensional wood grain in the embodiment 1 of the present application.

[0141] Figure 7 The schematic representation chart of the steps (S.9) - (S.11) for preparing the non-polyvinyl chloride wood-plastic board with three-dimensional wood grain in the embodiment 1 of the present application.

[0142] Figure 8 The schematic representation chart of the steps (S.12) - (S.13) for preparing the non-polyvinyl chloride wood-plastic board with three-dimensional wood grain in the embodiment 1 of the present application.

[0143] Figure 9 The board photo of the non-polyvinyl chloride wood-plastic board produced by using the attached bottom material in the scheme 1 as the raw material in the embodiment 1 of the present application after the end of the warping test.

[0144] Figure 10 The board photo of the non-polyvinyl chloride wood-plastic board produced by using the attached bottom material in the comparative scheme 2 as the raw material in the embodiment 1 of the present application after the end of the warping test.

[0145] Figure 11 The board photo of the polyvinyl chloride wood-plastic board produced by using the attached bottom material in the comparative scheme 5 as the raw material in the embodiment 1 of the present application after the end of the warping test. DETAILED DESCRIPTION

[0146] The present invention will be further described below with reference to specific embodiments. Those skilled in the art will be able to implement the present invention based on these descriptions. Furthermore, the embodiments of the present invention described below are generally only some, not all, of the embodiments of the present invention. Therefore, all other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort should fall within the scope of protection of the present invention.

[0147] The difference between the non-PVC wood-plastic composite board with three-dimensional wood grain described in this invention and the existing PVC wood-plastic composite board with three-dimensional wood grain is that the material of the substrate has been changed. Therefore, during the preparation process using the original method, the adhesion between the non-PVC wood-plastic substrate layer and the surface three-dimensional layer is relatively weak. As a result, the non-PVC wood-plastic composite board is prone to delamination, warping and cracking after being made into flooring. Therefore, the following series of embodiments will be used to describe this application in detail.

[0148] Example 1

[0149] In this embodiment, an adhesion substrate material capable of stable bonding with polyolefin resins with a surface energy not exceeding 35 dynes / cm is provided. This material is a photocurable resin composition consisting of a main resin, an auxiliary resin, an active diluent, a photoinitiator, a filler, and additives.

[0150] In this photocurable resin composition:

[0151] The main resin is preferably a photocurable resin that simultaneously contains photosensitive groups, hydrogen bond donor groups, and hydrogen bond acceptor groups. Further, the main resin needs to contain any one of the following: amide groups, imide groups, amino groups, urethane groups, hydroxyl groups, and urea groups. Moreover, the amount of the main resin added accounts for 30wt%-40wt% of the total mass of the photocurable resin composition.

[0152] The amount of auxiliary resin added shall not be less than 25 wt% of the amount of main resin added, and not more than 50 wt% of the amount of main resin added.

[0153] The reactive diluent contains at least two branched chains with an acrylic acid structure. Further, the reactive diluent can be any one of tripropanol diacrylate (TPGDA), trimethylolpropane triacrylate (TMPTA), and pentaerythritol triacrylate (PETA), and the amount of reactive diluent added is not less than 40 wt% and not more than 65 wt% of the amount of main resin added.

[0154] The photoinitiator can be a free radical photoinitiator, and the addition amount is 3wt%-5wt% of the total mass of the photocuring resin composition.

[0155] The filler can be any one or a combination of two or more of silicon dioxide, calcium carbonate, aluminum oxide, titanium dioxide, magnesium oxide, talc powder, wollastonite powder, mica powder, precipitated barium sulfate, bentonite, calcium carbonate powder, and ultra-fine aluminum silicate, and the addition amount is 20wt%-30wt% of the total mass of the photocuring resin composition.

[0156] The auxiliary agent can be a heat stabilizer, a leveling agent, a defoaming agent, and the like, and the addition amount is 0.5wt%-1wt% of the total mass of the photocuring resin composition.

[0157] Table 1 and Table 2 below are some typical schemes and comparative schemes prepared according to the above photocuring resin composition formulation.

[0158] Table 1

[0159]

[0160] Table 2

[0161]

[0162] The photocuring resin compositions in schemes 1-3 and comparative schemes 1-4 are coated on the surface of the non-polyvinyl chloride wood-plastic panel, and a non-polyvinyl chloride wood-plastic panel with three-dimensional wood grain is prepared.

[0163] The specific steps of the non-polyvinyl chloride wood-plastic panel with three-dimensional wood grain include the steps shown in Figure 1

[0164] (S.1) A SPC non-polyvinyl chloride wood-plastic panel with a length of 1260mm, a width of 970mm, and a thickness of 4.85mm is placed on the surface of a conveying device moving in a fixed direction, and the non-polyvinyl chloride wood-plastic panel (in this embodiment, the formulation of the non-polyvinyl chloride wood-plastic panel is as follows: polypropylene (surface tension 31mN / m) 47.5wt%, wood powder 15wt%, stone powder 35wt%, antioxidant 1wt%, lubricant 1wt%, and ultraviolet resistance agent 0.5wt%);

[0165] (S.2) The non-polyvinyl chloride wood-plastic panel first passes through a first roller coater during conveying, and the surface of the roller of the coater is attached with the photocuring resin composition in schemes 1-3 and comparative schemes 1-4, and 12g / m 2 of the photocuring resin composition is coated on the surface of the SPC panel during the contact between the non-polyvinyl chloride wood-plastic panel and the roller, and 395nm and 8W / cm 2 ​UV lamp curing, so that the primer forms an adhesive bottom.

[0166] In addition, in the present embodiment, the inventors also provide a comparative scheme 5 which uses a traditional polyvinyl chloride wood-plastic substrate layer and the adhesive bottom material described in scheme 1. The formula of the polyvinyl chloride wood-plastic board is as follows: polyvinyl chloride (surface tension 39 mN / m) 45 wt%, wood powder 15 wt%, stone powder 34 wt%, antioxidant 2 wt%, lubricant 2.5 wt%, ultraviolet resistance agent 1.5 wt%.

[0167] The adhesion of the non-polyvinyl chloride wood-plastic substrate layer and the adhesive bottom in schemes 1-3 and comparative schemes 1-4 was tested according to the method described in ASTM D3359, and the adhesion of the polyvinyl chloride wood-plastic substrate layer and the adhesive bottom in comparative scheme 5 was also tested. The test results are shown in Table 3 below.

[0168] Table 3 Adhesion test results of different types of photocurable resin compositions

[0169]

[0170] The cross-hatch test results of the adhesive bottom material in scheme 1 and the polyvinyl chloride wood-plastic substrate layer are shown in Figure 2 . The results of scheme 2 and scheme 3 are similar, so they are not shown here. From the combination of Table 1 and Figure 1 , it can be seen that the adhesive bottom used in the present application has good adhesion effect with the PP substrate. In Figure 3 , the left side is a cross-hatch test result graph of the adhesive bottom material in comparative scheme 2 and the polyvinyl chloride wood-plastic substrate layer, Figure 3 , the right side is a cross-hatch test result graph of the adhesive bottom material in comparative scheme 4 and the polyvinyl chloride wood-plastic substrate layer. From the results in Figure 3 , it can be seen that the adhesion between the adhesive bottom and the PP substrate is greatly reduced after replacing the adhesive bottom, which is not conducive to the stability and durability of the board. In addition, Figure 4 , is a cross-hatch test result graph of the combination of the adhesive bottom material in scheme 1 and the traditional polyvinyl chloride wood-plastic substrate layer in comparative scheme 5. From the graph, it can be seen that it is difficult to use the adhesive bottom in the present application to achieve high-strength adhesion with the traditional polyvinyl chloride wood-plastic substrate layer. This shows that the adhesive bottom used in the present application has good selectivity for polyolefin substrates.

[0171] Taking the adhesive bottom material in scheme 1 as an example, by attaching different weights of photocurable resin compositions on the surface of the non-polyvinyl chloride wood-plastic board, the effect of the weight of the photocurable resin composition on the adhesion between the non-polyvinyl chloride wood-plastic substrate layer and the adhesive bottom was explored. The results are shown in Table 4 below.

[0172] Table 4 Adhesion test results of different adhesion weights

[0173]

[0174] As shown in Figure 5 , (S.3) the non-polyvinyl chloride wood plastic board obtained in step (S.2) is further passed through a second roller coater, the surface of the coating roller of which is attached with a photocurable white paint (the white paint contains 50wt% photocurable epoxy HYS01-1, 30wt% titanium white powder, 5wt% photoinitiator 184, 0.5wt% photoinitiator TPO, 14.5wt% diluent hydroxyethyl acrylate), and during the contact of the SPC board with the coating roller, 18g / m 2 of white paint is coated on the surface of the primer, and after curing with a UV lamp of 395nm and 8W / cm 2 , a white color paint layer is obtained.

[0175] (S.4) the non-polyvinyl chloride wood plastic board obtained in the previous step is transported to a first inkjet printer, so that the surface of the color paint layer is sprayed with 6-8g / m 2 of ink by the first inkjet printer, and after curing of the ink, a two-dimensional pattern layer with a wood grain pattern is formed on the surface of the primer layer.

[0176] Further, as shown in Figure 6 , (S.5) the non-polyvinyl chloride wood plastic board obtained in the previous step is transported to a third roller coater, and 45g / m 2 of a photocurable resin liquid (the resin liquid contains 40wt% polyurethane acrylate, 5wt% silicon dioxide, 15wt% hydroxyethyl acrylate, 30wt% aluminum oxide, 5wt% photoinitiator 184, 0.5wt% photoinitiator TPO, 4.5wt% diluent) is roller coated on the surface of the two-dimensional pattern layer, and after curing by irradiation with a UV lamp of 395nm and 8W / cm 2 and a Hg lamp of 160w / cm 2 , a wood grain primer layer is formed.

[0177] (S.6) the non-polyvinyl chloride wood plastic board obtained in the previous step is transported to a fourth roller coater, so that the coating roller of the fourth roller coater is roller coated with 80g / m 2 of a resin liquid (the resin liquid contains 40wt% polyurethane acrylate, 5wt% silicon dioxide, 15wt% hydroxyethyl acrylate, 30wt% aluminum oxide, 5wt% photoinitiator 184, 0.5wt% photoinitiator TPO, 4.5wt% diluent) on the surface of the wood grain primer layer along the direction of transportation of the non-polyvinyl chloride wood plastic board (the direction of rotation of the roller itself is clockwise).

[0178] (S.7) After the first layer of resin solution is coated, the non-PVC wood-plastic board is conveyed along the surface of the conveying device, and it is ensured that the fourth roller coater does not apply any force to the resin solution before it is conveyed to the next roller coater.

[0179] (S.8) The non-PVC wood-plastic board obtained in the previous step is conveyed to the fifth roller coater, and the coating roller of the fifth roller coater continues to roll 75 g / m 2 of resin solution against the conveying direction of the non-PVC wood-plastic board (the rotation direction of the roller itself is clockwise).

[0180] Further, as shown in Figure 7 (S.9), the non-PVC wood-plastic board obtained in the previous step is conveyed to the second inkjet printer, so that 6 g / m 2 - 8 g / m 2 of embossing solution (the embossing solution contains 45.5 wt% dipropylene glycol monomer PEG600DA, 20.5 wt% p-hydroxyanisole HQMME, 10 wt% 2-tert-butyl hydroquinone MTBHQ, and 24 wt% diethylene glycol butyl ether) is sprayed on the surface of the resin solution, and the embossing solution penetrates downward into the resin solution and mixes with the resin solution to form an embossed layer.

[0181] (S.10) The part of the resin solution on the surface of the non-PVC wood-plastic board obtained in the previous step, except for the embossed layer, is irradiated in turn by a UV lamp of 395 nm and 8 W / cm 2 and a Hg lamp of 160 w / cm 2 to cure deeply.

[0182] (S.11) The non-PVC wood-plastic board obtained in the previous step is conveyed to a cleaning device containing a steel brush, so that the embossed layer is brushed off by the steel brush to form a three-dimensional wood grain layer.

[0183] Further, as shown in Figure 8 (S.12), the non-PVC wood-plastic board obtained in the previous step is conveyed through the sixth roller coater and a UV lamp of 395 nm and 8 W / cm 2 of UV, so that 12 g / m 2 of first topcoat is coated on the surface of the three-dimensional wood grain layer and is cured to obtain a first topcoat layer.

[0184] (S.13) The non-PVC wood-plastic board obtained in the previous step is conveyed through the seventh roller coater and a UV lamp of 395 nm and 8 W / cm 2 of UV, so that 12 g / m 2 of second topcoat is coated on the surface of the first topcoat layer and is cured to obtain a second topcoat layer.

[0185] Product test:

[0186] Product qualification test: 50 pieces of the board in each of the above-mentioned methods of production of Scheme 1 to Scheme 3, Comparative Scheme 1 to Comparative Scheme 5 were observed for cracking and delamination. The boards with visible quality problems were recorded as unqualified. Then the temperature in the constant temperature drying oven was set to 80°C, and the samples were placed in the constant temperature drying oven together with the aluminum plate for 6h, and then the samples were taken out together with the aluminum plate, and the qualification rate was observed.

[0187] Warpage test: the board was cut into a sample of 240mm*240mm, the wear-resistant layer was placed on the aluminum plate, and the sample was placed in a constant temperature drying oven at 80°C for 6h, and then the sample was taken out and placed in a constant temperature drying oven at 23±2°C and 50±5%RH for 24h. The average initial warpage of the board was measured by a caliper.

[0188] The test results of the product qualification test and the warpage test are shown in Table 5.

[0189] Table 5 Performance test results

[0190]

[0191] Figure 9 The board photo of the non-polyvinyl chloride wood-plastic board produced by the above method and using the attached bottom material in Scheme 1 as raw material after the warpage test, from which it can be seen that after 80°C and 6h heating, the board can still maintain a flat state, indicating that it has good anti-warpage performance. Figure 9 Figure 10 The board photo of the non-polyvinyl chloride wood-plastic board produced by the above method and using the attached bottom material in Comparative Scheme 2 as raw material after the warpage test, from which it can be seen that after 80°C and 6h heating, the board has a certain warpage. Figure 9 Figure 11 The board photo of the polyvinyl chloride wood-plastic board produced by the above method and using the attached bottom material in Comparative Scheme 5 as raw material after the warpage test, from which it can be seen that the sample presents strong warpage, indicating that compared with polypropylene material, polyvinyl chloride has a lower Vicat softening point, and thus after 80°C and 6h heating, it has a large deformation warpage, indicating that the polyolefin wood-plastic board has a significant advantage in heat resistance compared with the polyvinyl chloride wood-plastic board.

[0192] Example 2-3

[0193] ​​Example 2 is different from Example 1 in that the formulation of the non-polyvinyl chloride wood-plastic panel in Example 1 is replaced, respectively, polypropylene is replaced by polyethylene and poly-4-methyl-1-pentene, and the photo-cured resin composition adopts scheme 1.

[0194] The prepared three-dimensional wood grain non-polyvinyl chloride wood-plastic panel is also tested by the same method, and the results are shown in Table 6.

[0195] Table 6

[0196]

[0197] The specific embodiments described herein are merely illustrative of the spirit of the present application. Those skilled in the art of the present application can make various modifications or supplements to the described specific embodiments or replace them with similar ways, but will not deviate from the spirit of the present application or exceed the scope defined by the appended claims.

Claims

1. A non-polyvinyl chloride wood-plastic panel having a three-dimensional wood grain, characterized in that, Comprising: a non-polyvinyl chloride wood-plastic substrate layer comprising a polyolefin-based resin having a surface tension of no more than 35 mN / m; an adhesive primer on one side of the non-polyvinyl chloride wood-plastic substrate layer; wherein, the surface tension of the adhesive primer is less than the surface tension of the polyolefin-based resin, and the difference between the surface tensions is less than 5 mN / m; a two-dimensional pattern layer attached to the adhesive primer away from the non-polyvinyl chloride wood-plastic substrate layer; wherein, the two-dimensional pattern layer comprises a plurality of connected or unconnected two-dimensional wood grain lines obtained by digital printing; a three-dimensional wear-resistant layer above the two-dimensional pattern layer, the three-dimensional wear-resistant layer comprising a three-dimensional base layer covering the entire two-dimensional pattern layer and a three-dimensional wear-resistant layer comprising at least a portion or all of a protrusion or a groove corresponding to the two-dimensional wood grain lines or the gaps between the two-dimensional wood grain lines in the two-dimensional pattern layer; a surface finish layer on the surface of the three-dimensional wear-resistant layer, at least a portion of the surface finish layer being lower than the upper surface of the three-dimensional wear-resistant layer.

2. The non-polyvinyl chloride wood-plastic panel with three-dimensional wood grain according to claim 1, wherein, the polyolefin-based resin is any one or a combination of polyethylene, polypropylene, polyisobutylene, ethylene-vinyl acetate copolymer, ethylene-polypropylene copolymer, ethylene-acrylic acid or acrylate copolymer, and poly-4-methyl-1-pentene.

3. The non-polyvinyl chloride wood-plastic panel with three-dimensional wood grain according to claim 1, wherein, the adhesion between the non-polyvinyl chloride wood-plastic substrate layer and the adhesive primer is grade 5B according to the method described in ASTM D3359.

4. The non-PVC wood-plastic panel with three-dimensional wood grain according to claim 1 or 2 or 3, characterized in that, the non-polyvinyl chloride wood-plastic substrate layer further comprises fillers and processing aids.

5. The non-polyvinyl chloride wood-plastic panel with three-dimensional wood grain according to claim 4, wherein, the fillers are wood powder and / or stone powder.

6. The non-polyvinyl chloride wood-plastic panel with three-dimensional wood grain according to claim 1, wherein, the adhesive primer is obtained by curing a photocurable resin composition; the photocurable resin composition comprises a main resin having a photosensitive group; the main resin further comprises a hydrogen bond donor group and a hydrogen bond acceptor group for forming hydrogen bonds.

7. The non-polyvinyl chloride wood-plastic panel with three-dimensional wood grain according to claim 6, wherein, the photocurable resin composition has a dynamic viscosity of 80 seconds to 250 seconds.

8. The non-polyvinyl chloride wood-plastic panel with three-dimensional wood grain according to claim 6, wherein, The adhesive bottom has a weight of 10 g / m 2 - 15 g / m 2 .

9. The non-PVC wood-plastic panel with three-dimensional wood grain of claim 6, wherein, the main resin comprises any one of an amide group, an imide group, an amino group, a carbamate group, a hydroxyl group, and a urea group.

10. The non-polyvinyl chloride wood-plastic panel with three-dimensional wood grain according to claim 6, wherein, the photocurable resin composition further comprises an auxiliary resin having a photosensitive group and an active diluent; at least one of the auxiliary resin and the active diluent comprises a hydrogen bond acceptor group.

11. The non-polyvinyl chloride wood-plastic panel with three-dimensional wood grain according to claim 10, wherein, The addition amount of the main resin is 30wt%-40wt% of the total mass of the photocuring resin composition; and The addition amount of the auxiliary resin is not higher than 50wt% of the addition amount of the main resin; The addition amount of the active diluent is not higher than 65wt% of the addition amount of the main resin.

12. The non-PVC wood-plastic board with three-dimensional wood grain according to claim 11, wherein The addition amount of the auxiliary resin is not lower than 25wt% of the addition amount of the main resin.

13. The non-PVC wood-plastic board with three-dimensional wood grain according to claim 11, wherein The addition amount of the active diluent is not lower than 40wt% of the addition amount of the main resin.

14. The non-PVC wood-plastic board with three-dimensional wood grain according to claim 11, wherein The active diluent contains at least two branched chains containing acrylic structure.

15. The non-PVC wood-plastic board with three-dimensional wood grain according to claim 14, wherein The active diluent is any one of tripropylene glycol diacrylate, trimethylolpropane triacrylate, pentaerythritol triacrylate.

16. The non-PVC wood-plastic board with three-dimensional wood grain according to any one of claims 6-15, wherein The photocuring resin composition further comprises a photoinitiator, a filler and an auxiliary agent.

17. The non-PVC wood-plastic board with three-dimensional wood grain according to claim 16, wherein The addition amount of the photoinitiator is 3wt%-5wt% of the total mass of the photocuring resin composition; The addition amount of the filler is 20wt%-30wt% of the total mass of the photocuring resin composition; The addition amount of the auxiliary agent is 0.5wt%-1wt% of the total mass of the photocuring resin composition.

18. The non-PVC wood-plastic board with three-dimensional wood grain according to claim 16, wherein The photoinitiator is a free radical photoinitiator.

19. The non-PVC wood-plastic board with three-dimensional wood grain according to claim 16, wherein The filler is any one or combination of silicon dioxide, calcium carbonate, aluminum oxide, titanium dioxide, magnesium oxide, talc powder, wollastonite powder, mica powder, precipitated barium sulfate, bentonite, calcium carbonate powder, ultra-fine aluminum silicate.

20. The non-PVC wood-plastic board with three-dimensional wood grain according to any one of claims 6-15, wherein The color hiding agent is contained in the adhesive bottom for hiding the color of the non-PVC wood-plastic substrate layer; The two-dimensional pattern layer is printed on the surface of the adhesive bottom.

21. The non-PVC wood-plastic board with three-dimensional wood grain according to any one of claims 6-15, wherein The surface of the adhesive bottom away from the non-PVC wood-plastic substrate layer is further covered with a color paint layer containing a color hiding agent; The two-dimensional pattern layer is printed on the surface of the color paint layer.

22. The non-PVC wood-plastic board with three-dimensional wood grain according to any one of claims 6-15, wherein The adhesive bottom is further covered with a color hiding film for hiding the color of the non-PVC wood-plastic substrate layer on the surface away from the non-PVC wood-plastic substrate layer. The two-dimensional pattern layer is printed on the surface of the color hiding film.

23. A method for preparing the non-polyvinyl chloride wood-plastic panel having a three-dimensional wood grain according to any one of claims 1 to 22, characterized by, The method comprises the following steps: providing a non-PVC wood-plastic substrate layer; applying a layer of photocuring resin composition on the surface of the non-PVC wood-plastic substrate layer, and curing the photocuring resin composition to obtain the adhesive bottom, so that the difference in surface energy between the adhesive bottom and the non-PVC wood-plastic substrate layer is less than 5 mN / m; printing on the adhesive bottom to obtain a two-dimensional pattern layer; three-dimensional printing on the surface of the two-dimensional pattern layer to obtain a three-dimensional wear-resistant layer; applying a topcoat on the surface of the three-dimensional wear-resistant layer, and curing the topcoat to obtain the topcoat layer.

24. The method according to claim 23, wherein the dynamic viscosity of the photocuring resin composition is 80-250 seconds; The application amount of the photocurable resin composition is 10 g / m 2 - 15 g / m 2 .

25. The method according to claim 23 or 24, wherein the two-dimensional pattern layer is directly printed on the surface of the adhesive bottom.

26. The method according to claim 25, wherein the photocuring resin composition further comprises a color hiding agent for hiding the color of the non-PVC wood-plastic substrate layer.

27. The method according to claim 23 or 24, wherein before printing the two-dimensional pattern layer, a color paint layer is further applied on the surface of the adhesive bottom, and the color paint layer is cured to form a color paint layer, and the two-dimensional pattern layer is directly printed on the surface of the color paint layer.

28. The method according to claim 23 or 24, wherein before printing the two-dimensional pattern layer, a color hiding film for hiding the color of the non-PVC wood-plastic substrate layer is further applied on the surface of the adhesive bottom by hot lamination, and the two-dimensional pattern layer is directly printed on the surface of the color hiding film.

29. Use of the non-PVC wood-plastic board with three-dimensional wood grain according to any one of claims 1-22 in floor panels, wall panels or ceiling panels.

Images