Panel for surface decoration and processing method thereof

Abstract

The invention provides a panel for surface decoration and a processing method thereof, and relates to the field of surface decoration, the panel for surface decoration and the process manufacturing method thereof are characterized in that a texture layer, an injection molding layer and a surface protection layer with specific components and structures are arranged, and optimized process parameters are combined, so that the surface decoration quality is improved; according to the invention, the combination of high simulation degree and lightweight structure of the natural stone texture is realized, the interlayer bonding strength and surface wear resistance are ensured, and the method has the advantages of high texture trueness, excellent structural strength and high production efficiency.

Description

Technical Field

[0001] The present application relates to the field of surface decoration, and in particular to a panel for surface decoration and a processing method thereof. Background Art

[0002] With the passage of time, consumer electronics and automobiles have become integral parts of people's lives. Consumers' rising demands for a higher quality of life have led to a trend toward diversification and personalization in the market for surface decoration materials. Traditional decorative materials are clearly insufficient in meeting diverse aesthetic needs, such as sophistication, luxury, and simplicity. Their monotonous textures and subpar quality are becoming increasingly prominent. Furthermore, existing technologies for achieving personalized decorative effects are complex and costly, hindering large-scale commercial application. In particular, existing technologies often compromise between texture fidelity, structural strength, and production efficiency. Natural stone decorative materials, while possessing a natural texture, are difficult to process and heavy; imitation stone composite materials, while lightweight, lack texture fidelity; and plastic-based decorative materials, while low-cost, lack a premium feel. Furthermore, insufficient bonding strength between functional layers and poor surface wear resistance also hinder the practical application of decorative materials. These technical bottlenecks severely restrict the widespread application of decorative materials in high-end consumer electronics, automotive interiors, and other fields. Addressing these issues, existing technologies urgently need improvement. Summary of the Invention

[0003] The purpose of the embodiments of the present application is to provide a panel for surface decoration and a processing method thereof, which can solve the above-mentioned technical problems.

[0004] The embodiment of the present application provides a panel for surface decoration, including a texture structure layer, a surface layer is provided on the upper end of the texture structure layer, and an injection structure layer is provided on the lower end of the texture structure layer. The texture structure layer is selected from natural rock or imitation natural stone, and the natural rock includes at least one of marble, granite, and limestone, and has a thickness of 0.3 to 2.0 mm; the imitation natural stone is composed of the following components: 40 to 70 wt% of stone powder (particle size ≤ 200 mesh); 20 to 50 wt% of resin (epoxy resin or polyester resin); a non-woven fabric base (gram weight 80 to 150 g / m2); 2) 5-15wt%; imitation stone grain additive (at least one of mica powder and metallic glitter powder) 2-8wt%; the surface has natural grain or artificially embossed imitation natural grain, and the grain depth is 0.05-0.5mm; the injection molding structure layer is made of thermoplastic plastic or thermosetting plastic, and is combined with the back of the textured stone layer through the injection molding process; the thermoplastic plastic is selected from at least one of polypropylene (PP), polyethylene (PE), acrylonitrile-butadiene-styrene copolymer (ABS), and polycarbonate (PC), with a thickness of 0.5-3.0mm; the thermosetting plastic is selected from at least one of epoxy resin and phenolic resin, with a thickness of 0.3-2.0mm; injection molding process parameters: melt temperature: 180-280℃ (thermoplastic plastic The surface layer is made of reactive polyurethane (PUR) and is covered on the upper surface of the textured stone layer by injection molding or potting. The PUR components include, by weight: 60-80 parts of polyol (functionality 2-4); 20-40 parts of isocyanate (NCO content 15-30%); 0.1-1.0 parts of catalyst (organic tin or amine); and 1-5 parts of ultraviolet absorber (benzotriazole or benzophenone). The thickness is 0.2-3.0 mm, the surface hardness (pencil hardness) is ≥2H, and the wear resistance (Taber abrasion) is ≤50 mg / 1000 revolutions.

[0005] Preferably, a transition bonding layer is provided between the textured stone layer and the injection molded structural layer, and the transition bonding layer is composed of the following components: 30-50 wt% of ethylene-vinyl acetate copolymer (EVA); 5-15 wt% of silane coupling agent (KH-550 or KH-570); 30-60 wt% of nano-silicon dioxide (particle size 10-50 nm); the thickness of the transition bonding layer is 0.01-0.1 mm, and interlayer bonding is achieved by a hot pressing process (temperature 100-150° C., pressure 1-5 MPa, time 10-30 s).

[0006] Preferably, functional particles are added to the surface protection layer, and the functional particles are selected from: thermal conductive particles (at least one of aluminum nitride and aluminum oxide, with a particle size of 1 to 10 μm and an addition amount of 5 to 20 wt%); or antibacterial particles (at least one of silver ion-loaded titanium dioxide and nano-zinc, with an addition amount of 1 to 5 wt%); or self-healing microcapsules (isocyanate prepolymer microcapsules, with a particle size of 50 to 200 μm and an addition amount of 3 to 10 wt%).

[0007] Preferably, the natural texture or artificially embossed imitation natural texture on the upper surface of the texture structure layer is sprayed with a transparent particle layer.

[0008] Preferably, reinforcing fibers are added to the injection molding structural layer, and the reinforcing fibers are selected from: glass fibers (short-cut fiber length 3 to 12 mm, addition amount 10 to 30 wt%); or carbon fibers (continuous fiber length 50 to 100 mm, addition amount 5 to 20 wt%); the angle between the fiber orientation direction and the injection molding flow direction is 0 to 45° to improve the tensile strength (≥80 MPa) and flexural modulus (≥3000 MPa) of the material.

[0009] A process for producing a surface decoration material comprises the following steps:

[0010] Step 1: Textured Stone Layer Preparation

[0011] (1) Natural stone cutting: Select natural stone slabs with a thickness of 0.3 to 2.0 mm and cut them into the target shape by laser cutting or water jet cutting, with the edge chamfer radius ≥ 0.5 mm;

[0012] (2) Imitation natural stone molding: stone powder, resin, non-woven fabric base and imitation stone grain additives are mixed in proportion, hot pressed (temperature 120-180°C, pressure 5-15 MPa, time 30-120 s), and then the grain is embossed by a texture roller;

[0013] Step 2: Injection molding of the structural layer

[0014] (1) Mold design: The depth of the injection mold cavity is 0.5 to 3.0 mm greater than the thickness of the textured stone layer, and a reinforcing rib structure is set on the back (rib height 0.3 to 1.0 mm, spacing 5 to 20 mm);

[0015] (2) Injection molding parameter setting: adjust the melt temperature, injection pressure and holding time according to the plastic material to ensure that the filling rate is ≥95% and there is no flash;

[0016] Step 3: Applying surface protection layer

[0017] (1) PUR injection molding / potting: After mixing the PUR components in proportion, cover the surface of the stone layer through an injection molding machine (screw speed 20-80 rpm) or potting equipment (vacuum degassing treatment);

[0018] (2) Curing process: Curing at a temperature of 20-40°C and a humidity of 40-70% RH for 4-24 hours, or accelerated curing by infrared radiation (wavelength 800-1200 nm) (time shortened to 1-3 hours).

[0019] Preferably, in step 2, the bonding strength between the injection molded structural layer and the textured stone layer is controlled by: (1) pre-treatment of the back of the stone layer: plasma treatment (power 50-200 W, time 30-120 s) or chemical etching (hydrofluoric acid solution with a concentration of 5-15%, treatment time 10-60 s) is used to increase the surface roughness; (2) mold temperature control: the mold is preheated to 40-80° C. before injection molding to reduce the temperature difference stress between the stone layer and the plastic melt.

[0020] Preferably, in step 3, the thickness of the PUR surface protective layer is precisely controlled by:

[0021] (1) Injection molding process: adopt multi-stage injection speed, the first stage speed is 10-30 mm / s, the second stage speed is 30-80 mm / s, control the flow of the melt front to avoid uneven thickness;

[0022] (2) Potting process: The PUR component is delivered by a quantitative pump, and the coating thickness is monitored in real time in combination with a laser rangefinder.

[0023] Preferably, in the step 1, the texture imitating natural stone is formed by the following methods: (1) 3D printing texture: using stereolithography 3D printing (SLA) or fused deposition modeling (FDM) to print three-dimensional texture on the surface of the stone powder-resin composite layer, with a layer thickness of 0.05 to 0.2 mm; (2) nanoimprinting texture: using a template with a nano-scale concave-convex structure (period 100 to 500 nm), and transferring the texture by hot pressing (temperature 150 to 200° C., pressure 5 to 10 MPa, time 30 to 60 s).

[0024] Preferably, in step 3, the curing process of the PUR surface protective layer is monitored by the following methods: (1) online detection: using an infrared spectrometer (wave number range 4000-400 cm -1 ) Real-time monitoring of the NCO group consumption rate, and the curing is determined to be complete when the NCO content is ≤0.5%; (2) Off-line detection: Determine the degree of curing by differential scanning calorimetry (DSC), and the degree of curing is required to be ≥95%.

[0025] Beneficial effects of the present invention:

[0026] The present application provides a panel for surface decoration and a process for manufacturing the same. By setting a texture layer, an injection molding layer and a surface protection layer with specific components and structures, combined with optimized process parameters, the panel achieves a combination of high simulation of natural stone texture and lightweight structure, while ensuring interlayer bonding strength and surface wear resistance. The panel has the advantages of high texture realism, excellent structural strength and high production efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] In order to more clearly illustrate the technical solutions of the embodiments of the present application, the following is a brief introduction to the drawings required for use in the embodiments. It should be understood that the following drawings only show certain embodiments of the present application and therefore should not be regarded as limiting the scope. For ordinary technicians in this field, other relevant drawings can be obtained based on these drawings without creative work.

[0028] Figure 1 This is a production flow chart in some embodiments of the present application;

[0029] Figure 2 This is a schematic diagram of the structure of some embodiments of the present application.

[0030] The reference numerals are:

[0031] 1. Texture structure layer; 2. Surface layer; 3. Injection molding structure layer. DETAILED DESCRIPTION

[0032] To make the objectives, technical solutions, and advantages of the embodiments of the present application more clear, the technical solutions in the embodiments of the present application will be clearly and completely described below in conjunction with the accompanying drawings of the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, not all of the embodiments. Generally, the components of the embodiments of the present application described and shown in the drawings herein can be arranged and designed in various different configurations.

[0033] Therefore, the following detailed description of the embodiments of the present application provided in the accompanying drawings is not intended to limit the scope of the present application for protection, but merely represents selected embodiments of the present application. All other embodiments obtained by persons of ordinary skill in the art based on the embodiments in the present application without creative work are within the scope of protection of the present application.

[0034] It should be noted that similar reference numerals and letters denote similar items in the following drawings, and therefore, once an item is defined in one drawing, it does not need to be further defined or explained in subsequent drawings.

[0035] In the description of this application, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," "outer," etc., indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings, or are the orientations or positional relationships in which the product of this application is typically placed when in use. These terms are intended only to facilitate the description of this application and simplify the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, be constructed, or operate in a specific orientation. Therefore, they should not be construed as limitations on this application. Furthermore, the terms "first," "second," "third," etc., are used only to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0036] Furthermore, terms such as "horizontal," "vertical," and "overhanging" do not necessarily imply that a component must be absolutely horizontal or overhanging, but rather that it can be slightly tilted. For example, "horizontal" simply means that its direction is more horizontal than "vertical," and does not mean that the structure must be completely horizontal, but rather that it can be slightly tilted.

[0037] It should also be noted that, in the description of this application, unless otherwise expressly specified or limited, the terms "disposed," "installed," "connected," and "connected" should be understood in a broad sense. For example, they can refer to fixed connections, detachable connections, or integral connections; they can refer to mechanical connections or electrical connections; they can refer to direct connections or indirect connections through an intermediate medium; and they can refer to internal connections between two components. Those skilled in the art will understand the specific meanings of the above terms in this application based on the specific circumstances.

[0038] In existing technologies, 3C products and automotive decorative materials are gradually evolving from traditional materials to high-end ones. However, existing technologies struggle to balance the conflict between diverse aesthetic needs and production costs. Traditional decorative materials often rely on direct processing of natural stone, resulting in high material costs and low processing efficiency. Using a single stone-imitation process also results in insufficient texture fidelity and poor wear resistance. For example, in the manufacture of automotive interior panels, achieving the luxurious feel of marble textures while controlling material thickness to reduce overall weight is crucial. Existing technologies struggle to simultaneously meet these requirements.

[0039] To address these issues, researchers conducted innovative explorations from the perspective of material composite structure and process synergy. They first analyzed the formation mechanism of natural stone's decorative effects and discovered that its texture hierarchy is directly related to the distribution of mineral particles. Based on this, they proposed using a stone powder composite resin to simulate the natural stone matrix and using additives to enhance the visual effect. They also noted that the combination of the injection molding process and the surface protective layer directly affects product durability, and thus designed a multi-layer composite structure to achieve functional integration. Through repeated experiments, they verified the compatibility of different resin systems with injection molding parameters, ultimately formulating a technical solution that balances aesthetics and cost.

[0040] Example 1

[0041] like Figure 1As shown, the present application proposes a panel for surface decoration, including a texture structure layer 1, a surface layer 2 is provided on the upper end of the texture structure layer 1, and an injection molding structure layer 3 is provided on the lower end of the texture structure layer 1; the texture structure layer 1 is selected from natural rock or imitation natural stone, and the natural rock includes at least one of marble, granite, and limestone; the imitation natural stone is composited by stone powder, resin, non-woven fabric base and imitation stone grain additive, and the surface has natural grain or artificially embossed imitation natural grain; the injection molding structure layer 3 is made of thermoplastic plastic or thermosetting plastic, and is combined with the back of the texture stone layer through an injection molding process; the surface layer 2 is made of reactive polyurethane, and is covered on the upper surface of the texture stone layer through an injection molding or potting process.

[0042] Among them, the non-woven fabric base in the texture structure layer 1 refers to a mesh structure material formed by directional or random arrangement of polymer fibers, which can be specifically achieved by polyester fiber or glass fiber woven fabric, and is used to enhance the crack resistance of the imitation stone layer; the mica powder in the imitation stone grain additive refers to a silicate mineral powder with a layered structure, which can be specifically achieved by wet-ground mica powder with a particle size range of 5-50 microns, and is used to produce the glitter effect of natural stone; the melt temperature in the injection molding process parameters refers to the flow temperature reached by the plastic raw material in the injection barrel, which can be specifically achieved by real-time monitoring and feedback control through thermocouples to ensure that the material is fully plasticized without decomposition; the reactive polyurethane of the surface layer 2 refers to a polymer prepolymer containing an active isocyanate group, which can be specifically achieved by using a terminal NCO group prepolymer generated by the reaction of polyols and excess isocyanate, and a dense protective layer is formed by moisture curing.

[0043] Specifically, this technical solution achieves the unity of decoration and function through the synergistic effect of a three-layer structure; the texture structure layer 1 serves as the visual presentation layer, and natural stone directly provides real texture, while the imitation stone replicates the natural texture through a precise ratio of stone powder and resin; the injection molding structure layer 3 serves as the supporting layer, and the selection of thermoplastic plastics takes into account both molding efficiency and mechanical strength, while thermosetting plastics are adapted to high-temperature use environments; the surface protection layer forms a transparent protection through a specifically formulated polyurethane material, and the cross-linked network generated during its curing process effectively resists wear; each layer of material is reliably combined through matching processing temperature and pressure parameters to avoid interlayer peeling problems; during the manufacturing process, the texture formation process of the imitation stone layer and the mold design of the injection molding layer cooperate with each other to ensure that the final product has both fine texture and structural stability.

[0044] Compared to existing technologies, traditional imitation stone decorative panels often use a single layer of composite material to directly imprint the texture, which can easily cause blurring or peeling. This solution, by independently providing a texture structure layer 1 and an injection molding structure layer 3, maintains the fineness of the texture while achieving rapid molding through the injection molding process. Existing technologies often use a spray coating process for the surface protective layer, which suffers from uneven coating and poor weather resistance. This solution uses a reactive polyurethane injection molding or potting process to form a continuous and dense protective layer. Furthermore, traditional processes rely on adhesives to bond the imitation stone layer to the base layer. This solution significantly improves the interlayer bonding strength through the hot-melt bonding method of the injection molding process.

[0045] This application effectively solves the problem of balancing the aesthetics and economy of decorative materials; in the application of automobile interior panels, the texture effect can be quickly changed by adjusting the type of additives in the imitation stone layer to meet the personalized needs of different models; in the manufacture of electronic product housings, the lightweight design of the injection-molded structural layer 3 combined with the wear-resistant properties of the surface protective layer extends the product life; actual tests show that while maintaining the visual effect of natural stone, the multi-layer composite structure reduces material costs by about 40% and improves production efficiency by more than 30%.

[0046] The present application further proposes to set a transition bonding layer between the textured stone layer and the injection molded structural layer 3. The transition bonding layer is composed of ethylene-vinyl acetate copolymer, silane coupling agent and nano-silicon dioxide. The thickness is controlled within the range of 0.01 to 0.1 mm, and interlayer bonding is achieved through a hot pressing process.

[0047] Among them, ethylene-vinyl acetate copolymer is used as the main bonding material. The polar groups in its molecular chain can form physical adsorption with the surface of inorganic stone, and at the same time produce molecular chain entanglement with the organic plastic layer, which is used to balance the interface compatibility between different materials; the silane coupling agent generates silicon hydroxyl chemical bonds on the surface of stone through hydrolysis reaction, and its organic end forms a covalent connection with ethylene-vinyl acetate copolymer, which is used to construct a chemical bridge between inorganic and organic materials; nano-silica is used as a reinforcing filler, and its nano-scale particle size can fill the interface micropores and form a three-dimensional network structure, which is used to inhibit the propagation of interface cracks; the temperature range of the hot pressing process is set to 100 to 150 degrees Celsius, which can ensure that the ethylene-vinyl acetate copolymer is fully melted and flows without damaging the substrate; the pressure range is controlled at 1 to 5 MPa, which is used to achieve full interface contact and maintain the dispersed structure of the nano-filler.

[0048] Specifically, the transition bonding layer achieves interface strengthening through the synergistic action of multiple components; ethylene-vinyl acetate copolymer penetrates into the micropores on the stone surface in the molten state to form a mechanical anchor, while its flexible chain segments can buffer the stress caused by thermal expansion differences; silane coupling agent forms a chemical bonding layer at the interface, effectively improving the bonding stability in a wet environment; nano-silicon dioxide is evenly dispersed in the bonding layer, improving the interlayer toughness by increasing the interface contact area and crack deflection effect; during the hot pressing process, the coordinated control of temperature and pressure allows the adhesive material to fully infiltrate the substrate surface, while avoiding excessive compression that may cause damage to the filler structure.

[0049] Compared with existing technologies, traditional bonding layers usually use single-component adhesives, which cannot simultaneously solve the problems of inorganic-organic material interface bonding and stress buffering. For example, although ordinary epoxy adhesives have high bonding strength, they are brittle and their thermal expansion coefficient is significantly different from that of the substrate. This solution introduces a stress buffering mechanism while maintaining high bonding strength through the design of a composite bonding system, and the addition of nanofillers makes the interface adaptive, which can effectively suppress the delamination phenomenon during thermal cycling.

[0050] Through the above-mentioned technical solution, this application achieves reliable bonding at the interface of heterogeneous materials, solving the technical problem of easy peeling between layers of traditional decorative panels, while also reducing the interfacial stress concentration caused by differences in the thermal expansion coefficients of the materials. This transition layer structure can adapt to the differences in the physical properties of different substrates and maintain stable interfacial bonding performance even in high temperature and high humidity environments.

[0051] This application further proposes a technical solution for adding functional particles to the surface protective layer. The functional particles are selected from at least one of the following types: thermally conductive particles, antimicrobial particles, or self-healing microcapsules. The thermally conductive particles are made of aluminum nitride or aluminum oxide, the antimicrobial particles are made of silver ion-loaded titanium dioxide or nano-zinc, and the self-healing microcapsules use an isocyanate prepolymer as the core material.

[0052] Among them, thermal conductive particles refer to inorganic fillers with high thermal conductivity, which can be specifically realized by using micron-sized aluminum nitride or aluminum oxide powder. By uniformly dispersing them in the matrix, a continuous heat conduction path is formed, thereby improving the thermal diffusion efficiency of the material; antibacterial particles refer to active ingredients that can inhibit the growth of microorganisms, which can be specifically realized by using titanium dioxide or nano-zinc particles loaded with silver ions, and a long-lasting antibacterial effect is achieved through the ion release mechanism; self-healing microcapsules refer to micro-containers that encapsulate repair agents, which can be specifically realized by using microcapsules with isocyanate prepolymers as the core material. When cracks appear on the surface of the material, the microcapsules rupture to release the repair agent and react with moisture in the environment to fill the cracks.

[0053] Specifically, the thermally conductive particles form a three-dimensional thermally conductive network in the surface protective layer, transfer heat through contact between particles, and effectively reduce local temperature accumulation; the antibacterial particles destroy the cell membrane structure of microorganisms and inhibit bacterial reproduction by slowly releasing silver ions or zinc ions; the self-healing microcapsules rupture when the material is mechanically damaged, and the released isocyanate prepolymer undergoes a cross-linking reaction with moisture in the air to generate polyurea to fill the crack area and restore the integrity of the material; the three functional particles are selected based on their physical and chemical properties and compatibility with the matrix material, so as to achieve additional functions without affecting the transparency and mechanical strength of the original coating.

[0054] Compared with existing technologies, traditional surface decoration materials usually only have a single decorative function and cannot meet the needs of heat dissipation of electronic equipment, antibacterial in medical environments, or self-repair after long-term use. If multifunctionality is to be achieved in existing technologies, it is often necessary to superimpose multiple layers of functional coatings, which leads to complex processes and increased costs. This solution realizes a multifunctional integrated design by compounding functional particles in a single protective layer, avoiding the interface bonding problems caused by multi-layer coatings.

[0055] Through the above technical solution, this application solves the technical defect of single function of surface decoration materials, and can flexibly select thermal conductivity, antibacterial or self-repairing functions according to the requirements of application scenarios; in the application of electronic equipment casing, the thermal conductivity function can effectively improve the heat dissipation performance; in the decoration of medical equipment, the antibacterial function can reduce the risk of cross-infection; on the surface of furniture that is frequently touched, the self-repairing function can extend the service life of the material; the addition amount of the three functional particles has been optimized to maintain the processing performance and optical properties of the surface protective layer while ensuring the effectiveness of the functions.

[0056] The present application further proposes that a transparent particle layer is sprayed on the natural texture or artificially embossed imitation natural texture on the upper surface of the texture structure layer 1.

[0057] The transparent particle layer refers to a discrete particle covering layer formed by transparent or translucent materials, which can be made of polyurethane, acrylic resin or silica-based materials. The particle size range can be 50-300 microns, and the refractive index range can be 1.4-1.6. This particle layer interacts with the surface concave and convex structure through optical refraction to enhance the visual layering. The spraying process refers to the use of compressed air or electrostatic spraying to evenly disperse the particles and attach them to the textured surface. Specifically, it can be achieved by fluidized bed spraying or high-pressure airless spraying equipment. This process ensures a particle coverage density of 100-500 particles / cm by controlling the air pressure, spray distance and movement speed. 2 , to avoid particle accumulation or local loss.

[0058] Specifically, a transparent particle layer is applied to the surface of a textured structure layer 1 on which natural or artificial embossed patterns have been formed; during the spraying process, the particles are embedded in the recessed areas of the patterns in a randomly distributed manner, forming a microscopic concave-convex structure; light undergoes multiple refractions and reflections between the transparent particles and the underlying patterns, creating a three-dimensional visual effect; the difference in hardness between the particle layer and the substrate further creates tactile feedback. For example, when the particle hardness is higher than that of the substrate, a subtle matte touch can be produced; the spraying process adapts to the needs of different application scenarios by adjusting the particle material and particle size. For example, high-refractive-index silica particles can enhance gloss, while matte polyurethane particles can reduce surface reflection.

[0059] Compared to existing technologies, traditional surface decoration materials typically increase gloss by applying a clear coating or laminating a transparent film, but this results in blurred texture details and a monotonous feel. Existing methods also use chemical etching to create microstructures, but these methods are complex and costly. This solution uses the targeted spraying of discrete particles to create a multi-layered optical effect through physical superposition while preserving the clarity of the original texture. The particle distribution is also more controllable than with traditional coating processes.

[0060] Through the above technical solution, the present application realizes the improvement of the visual level and tactile diversity of decorative materials through surface treatment without changing the underlying texture preparation process; the combination of the transparent granular layer and the spraying process effectively balances the contradiction between the improvement of decorative effects and the control of production costs, and solves the technical problems of high-cost processes and low-level performance in the existing technology; the discrete characteristics of the granular layer avoid material waste, and at the same time provide flexible adjustment space for personalized decoration needs.

[0061] The present application further proposes a technical solution for adding reinforcing fibers to the injection molded structural layer 3, wherein the reinforcing fibers are selected from glass fibers or carbon fibers; the glass fibers are in the form of chopped fibers and the length is controlled within a range of 3 to 12 mm, and the amount added can be 10 to 30 weight percent; the carbon fibers are in the form of continuous fibers and the length is controlled within a range of 50 to 100 mm, and the amount added can be 5 to 20 weight percent; the fiber orientation direction forms an angle of 0 to 45 degrees with the injection molding flow direction.

[0062] Among them, chopped glass fiber refers to a non-continuous fiber form whose length is cut into millimeter level, which can be achieved by mechanical cutting or melt drawing process. Its dispersed distribution characteristics help to form a three-dimensional reinforcement network during the injection molding process; continuous carbon fiber refers to a long fiber form that maintains the axial continuity of the fiber, which can be achieved by prepreg laying or online impregnation process. Its continuous structure can effectively transfer loads; fiber orientation control refers to arranging the fibers at a predetermined angle through mold runner design or injection molding parameter adjustment, which can be achieved by a multi-gate system or variable temperature process. This angle range balances the fiber dispersion and directional consistency requirements.

[0063] Specifically, chopped glass fibers are randomly dispersed in the molten plastic to form a spatial support structure. When the material is loaded, stress is transferred through the fiber-matrix interface, thereby improving the overall deformation resistance. When continuous carbon fibers are arranged along the main stress direction, their high modulus characteristics can significantly improve the bending stiffness of the structural component. The control of the fiber orientation angle is achieved by adjusting the interaction between the injection molding flow field and the fiber motion trajectory, so that the fibers form an orderly but not completely parallel arrangement during the flow process, avoiding brittle fracture caused by excessive reinforcement in a single direction and preventing strength loss caused by disordered arrangement. The combined application of the two fiber morphologies allows the injection molded structural layer 3 to be locally reinforced according to the mechanical requirements of different regions, such as arranging continuous fibers in stress concentration areas and using chopped fibers in general load-bearing areas.

[0064] Compared to existing technologies, traditional reinforced injection molded parts typically use a single fiber type without controlled orientation angles, resulting in significant material anisotropy or low reinforcement efficiency. This solution, through the coordinated control of fiber morphology and orientation, ensures that the spatial distribution of the fiber reinforcement phase more closely matches the actual stress state while maintaining the feasibility of the injection molding process. Compared to conventional disordered short fiber reinforcements, the aligned continuous fibers effectively transfer loads throughout the structure. Compared to fully oriented long fiber reinforcements, the limited angle of orientation control reduces molding difficulty and equipment costs.

[0065] Through the above technical solution, this application effectively resolves the contradiction between lightweight and mechanical performance of the injection-molded structural layer 3. The addition of chopped glass fiber improves overall strength while ensuring processing fluidity, and the introduction of continuous carbon fiber specifically strengthens key load-bearing areas. The optimized design of fiber orientation angles reduces material anisotropy, allowing the structural component to maintain stable performance when subjected to forces in different directions. This technical solution provides a composite structural layer for surface decorative panels that combines lightweight and high strength, while also adapting to diverse application scenarios through flexible combinations of fiber types and arrangements.

[0066] Example 2

[0067] like Figure 2 As shown, the present application further proposes a process for producing surface decorative materials, comprising the following steps: in a textured stone layer preparation stage, natural stone is cut into a target shape by laser cutting or water jet cutting, and the natural stone is imitated by hot pressing and then embossed with a pattern; in an injection molding structural layer 3 molding stage, the mold cavity depth is matched with the texture layer thickness and reinforcing ribs are set, and the injection molding parameters are adjusted to ensure the filling rate; in a surface protection layer application stage, the PUR layer is covered by an injection molding or potting process and the curing conditions are controlled.

[0068] Among them, laser cutting or water jet cutting refers to a processing method that uses high-energy beams or high-pressure water flow to precisely cut natural stone. Specifically, it can be achieved by using a laser with a power of 500-2000W or a water jet system with a pressure of 300-400MPa. This feature avoids material damage through non-contact processing while meeting the processing requirements of complex shapes; hot pressing refers to the process of forming a dense structure of mixed materials under specific temperature and pressure. Specifically, it can be implemented using a hydraulic press with a heating plate. This feature improves the mechanical strength of imitation stone through physical cross-linking; texture roller embossing refers to the process of transferring patterns to the surface of the material through a roller with concave and convex patterns. Specifically, it can be implemented using a surface hardness of HRC50. -60 steel pressure roller, which enables the imitation stone to obtain a controllable three-dimensional texture effect; injection mold cavity depth matching refers to the design of the corresponding relationship between the mold cavity size and the substrate thickness. Specifically, the mold processing can be carried out after obtaining the substrate thickness data through 3D scanning. This feature ensures the dimensional adaptability of the injection layer and the texture layer; the reinforcement structure refers to the raised support structure set on the back of the injection layer, which can be designed with a trapezoidal or semicircular cross-section. This feature improves the overall deformation resistance by increasing the sectional inertia moment; PUR injection molding / potting refers to the process of injecting liquid polyurethane material into molding or pouring it into covering. Specifically, the ratio of the two components can be controlled by a metering mixing system. This feature forms a dense protective layer through chemical reaction.

[0069] Specifically, in the preparation of the texture layer, the natural stone cutting process achieves precise cutting through energy density control, and the chamfering treatment effectively prevents the edges of thin stones from breaking; the imitation stone components form a uniform composite material matrix under hot pressing conditions, and the periodic embossing action of the texture roller produces continuous bionic patterns; in the injection molding stage, the depth compensation design of the mold cavity allows thickness tolerance of the substrate, and the grid distribution of the reinforcement optimizes the mechanical property distribution of the injection molding layer. The coordinated control of the melt temperature and pressure ensures that the plastic fully fills the mold cavity; in the surface treatment process, the PUR material eliminates component segregation through dynamic mixing, and vacuum degassing treatment removes pores inside the coating. The temperature and humidity control of the curing process allows the polymer chains to be arranged in order to form a dense cross-linked network.

[0070] Compared with existing technologies, traditional processes are prone to edge chipping when cutting stone. This method effectively avoids damage to thin substrates by controlling the chamfer radius; existing imitation stone preparation mostly uses single molding, resulting in a single texture. This method achieves adjustable texture through independent hot pressing and embossing processes; conventional injection molding processes are difficult to adapt to thickness fluctuations of ultra-thin substrates. This method improves product qualification rate through mold cavity depth compensation design; traditional surface coatings have the problem of poor leveling. This method uses a combination of graded injection molding speed and vacuum degassing to ensure coating uniformity.

[0071] Through the above technical solutions, this application realizes the efficient customized production of decorative materials, the flexible selection of natural and imitation stone materials meets different aesthetic needs, the optimized combination of injection molding process parameters reduces the scrap rate, the controllable molding process of the surface protective layer reduces the subsequent processing steps, and the synergistic effect of the overall process flow significantly reduces the production cost of personalized products.

[0072] The present application further proposes that the bonding strength between the injection molded structural layer 3 and the textured stone layer is achieved by controlling the pretreatment method of the back of the stone layer and the mold temperature; the pretreatment of the back of the stone layer can be achieved by plasma treatment or chemical etching, and the mold temperature is controlled to be preheated to 40 to 80 degrees Celsius before injection molding.

[0073] Among them, plasma treatment refers to the use of high-energy particles to bombard the stone surface to form a micron-scale concave and convex structure. Specifically, this can be achieved by using a plasma device with a power of 50 to 200 watts for 30 to 120 seconds. This treatment improves the interfacial bonding strength by increasing the contact area and the mechanical interlocking effect. Among them, chemical etching refers to the selective dissolution of the surface components of the stone by a hydrofluoric acid solution to form a porous structure. Specifically, it can be achieved by using a hydrofluoric acid solution with a concentration of 5% to 15% for 10 to 60 seconds. This etching avoids excessive damage to the integrity of the stone layer while ensuring reaction efficiency. Among them, mold temperature control refers to reducing the temperature difference between the melt and the stone by preheating the mold. Specifically, it can be achieved by heating the mold to 40 to 80 degrees Celsius before injection molding. This temperature range not only meets the molding requirements of different plastics, but also reduces the interfacial stress caused by differences in thermal expansion and contraction.

[0074] Specifically, plasma treatment or chemical etching of the backside of the stone layer increases its surface roughness, allowing the melt to fully fill the microstructure during the injection molding process, forming a mechanical interlock. Mold preheating reduces the temperature gradient between the melt and the stone layer, suppressing differential shrinkage caused by temperature differences during solidification and thus reducing the risk of interface defects. These two methods work synergistically to strengthen the physical bond while preventing interlayer separation caused by thermal stress.

[0075] Compared with existing technologies, traditional methods usually rely solely on adhesives or single surface treatments, without simultaneously optimizing interface morphology and controlling thermal stress. In existing technologies, mold temperatures are often below 40 degrees Celsius, resulting in rapid cooling of the melt upon contact with the stone, which can easily lead to microcracks at the interface. This application combines surface modification with gradient temperature control to achieve a stable bond without the need for an additional adhesive layer.

[0076] Through the above technical solution, the present application effectively solves the delamination problem caused by insufficient bonding strength between the injection-molded structure layer 3 and the textured stone layer, while reducing the probability of interface defects; the synergistic effect of the surface treatment of the stone layer and the mold temperature control significantly improves the interface bonding performance, and the production process can be stably implemented without complex process adjustments, thereby improving product yield and reliability.

[0077] The present application further proposes to perform dual monitoring of the curing state of the PUR surface protection layer by combining online detection and offline detection during the curing process of the surface protection layer.

[0078] Among them, online detection by infrared spectrometer refers to the use of infrared absorption spectra within a specific wavenumber range to track the concentration changes of isocyanate groups in real time. Specifically, it can be achieved by using a Fourier transform infrared spectrometer in conjunction with a flow detection cell. By collecting the changes in the characteristic peak intensity of the NCO group in the reaction system in real time, its consumption rate is calculated; offline detection by differential scanning calorimetry refers to quantifying the degree of curing reaction by measuring the heat flow changes of the material under programmed temperature control. Specifically, the sample can be encapsulated in a standard aluminum crucible and then subjected to a temperature scan. The degree of curing is determined by calculating the ratio of the reaction exothermic peak area to the theoretical total heat.

[0079] Specifically, during the PUR curing stage, an infrared spectrometer continuously monitors the NCO group concentration in the molten mixture. When the concentration drops below a set threshold, a curing termination signal is automatically triggered. Offline testing, after curing is complete, verifies the completion of the curing reaction through thermal analysis, forming a closed-loop control system. Online testing provides real-time feedback to optimize process parameters, while offline testing serves as the final quality verification tool. Together, they ensure that the curing state of each batch of product meets preset standards.

[0080] Compared to existing technologies, traditional processes typically rely on a single curing time control or simple hardness test, failing to track the progress of chemical reactions in real time. Existing offline sampling and testing techniques also suffer from lags, making it difficult to avoid quality fluctuations within batches. This solution, by combining online spectral analysis with offline thermal analysis, achieves for the first time the quantitative, full-process monitoring of the curing reaction, overcoming the limitations of traditional empirical process control.

[0081] Through the above technical solution, this application effectively solves the problems of uneven hardness and fluctuating wear resistance of the surface protective layer caused by inaccurate curing monitoring. By real-time monitoring of the NCO group consumption rate, the curing endpoint can be accurately determined, avoiding softening defects of the surface layer 2 caused by incomplete reaction. Combined with DSC testing of the degree of cure, curing anomalies caused by fluctuations in ambient temperature and humidity can be effectively identified, ensuring that each batch of products achieves stable mechanical performance indicators.

[0082] This application further proposes that the texture of imitating natural stone is formed by two methods: using photocuring 3D printing or fused deposition modeling to print three-dimensional texture on the surface of the stone powder-resin composite layer, and controlling the layer thickness within a specific range; using a template with a nano-scale concave-convex structure to transfer the texture through a hot pressing process.

[0083] Among them, photocuring 3D printing refers to an additive manufacturing technology that uses ultraviolet light to irradiate liquid photosensitive resin to solidify it layer by layer. Specifically, it can be achieved using a laser scanning system. Its layer thickness is controlled by adjusting the spot diameter and slicing parameters. This technology can achieve micron-level precision texture construction. Fused deposition modeling refers to a manufacturing method that extrudes thermoplastic material by heating and stacking it layer by layer. Specifically, a multi-axis motion platform can be used to control the extrusion path. Its layer thickness is adjusted by the nozzle diameter and feed speed. This technology is suitable for quickly generating large-scale textures. Nano-scale concave-convex structure templates refer to metal or silicon-based molds with periodic micro-nano structures on the surface. Specifically, they can be prepared using electron beam lithography or reactive ion etching processes. Its periodic range is controlled by the template design parameters. This structure can replicate the microtexture characteristics of natural stone. The temperature and pressure parameters in the hot pressing process are determined by matching the material softening point with the template strength. This combination of parameters ensures the integrity of the texture transfer while avoiding damage to the substrate.

[0084] Specifically, in the stone powder-resin composite layer molding stage, customization of the surface decoration effect is achieved by selectively superimposing two texture formation technologies; photocuring 3D printing cures the resin-based composite material by exposure layer by layer, and accurately constructs macroscopic three-dimensional textures within the preset layer thickness range, and its molding accuracy can be adapted to different design requirements; fused deposition molding quickly forms decorative textures with continuous gradient characteristics through molten material extrusion path planning; the nanoimprinting process utilizes the microstructure of the template to transfer nanoscale textures to the material surface under hot pressing conditions. This process controls the hot pressing parameters to allow the resin material to fully fill the template depressions, and after cooling and shaping, a surface structure similar to the micromorphology of natural stone is formed; the coordinated application of the two processes enables the surface decorative layer to have both macroscopic three-dimensional effects and microscopic texture characteristics, and the adjustability of the processing parameters provides a technical implementation path for different decorative styles.

[0085] In some specific embodiments, the photocuring 3D printing equipment can be configured with a multi-wavelength light source system, for example, using a 405nm ultraviolet laser in combination with a digital micromirror device to achieve high-precision exposure; the extrusion mechanism of the fused deposition modeling can be equipped with a nozzle with a diameter of 0.2-0.4mm, and the single-layer molding thickness can be controlled by adjusting the feeding speed; the nanoimprint template can adopt a nickel-based electroforming mold, and its surface is modified with fluorosilane to improve the demolding performance; the hot pressing equipment can be integrated with a temperature gradient control system, for example, during the pressing stage, the template temperature is kept 5-10°C higher than the substrate temperature to promote material flow and filling.

[0086] Compared with existing technologies, traditional imprinting processes are limited by mold processing accuracy and cost, making it difficult to quickly prepare complex three-dimensional patterns; conventional mechanical engraving methods have the defects of low processing efficiency and large material loss, and a single surface treatment technology cannot take into account the coordinated expression of macro and micro textures; this solution combines additive manufacturing technology with nanoimprinting, retaining the advantages of 3D printing in complex modeling, and using nanoimprinting to achieve efficient replication of micro textures, while reducing the implementation difficulty of multi-process integration through parameter optimization.

[0087] Through the above technical solution, this application can flexibly select the pattern formation method according to user needs, significantly reducing the mold development cost while ensuring the realism of the decorative effect; for small-batch personalized orders, 3D printing can be used to directly generate customized patterns; for large-scale production needs, efficient replication can be achieved through nano-imprinting templates; the combined application of the two processes makes the production of surface decorative materials both economical and flexible, solving the contradiction between personalized needs and production costs in traditional processes.

[0088] The present application further proposes a dual monitoring method combining online detection and offline detection during the curing process of the surface protective layer; the online detection monitors the isocyanate group consumption rate in real time through an infrared spectrometer, and the reaction is determined to be complete when the content drops below 0.5%; the offline detection determines the degree of curing of the material through differential scanning calorimetry, which is required to reach more than 95%.

[0089] Among them, infrared spectrometers are analytical instruments that use spectral absorption characteristics within a specific wavenumber range to track changes in chemical groups. Specifically, this can be achieved using a Fourier transform spectrometer. Their function is to dynamically capture changes in isocyanate group concentration and determine the reaction progress in real time. Differential scanning calorimetry, a method that analyzes the degree of crosslinking by measuring changes in the material's heat flow, can be achieved using standard DSC equipment. Its function is to quantitatively assess the molecular crosslinking state of the cured material. The NCO group consumption rate refers to the conversion ratio of the isocyanate component during the reaction. Online monitoring of this indicator can avoid the problems of insufficient reaction or overcuring caused by traditional time control methods. The degree of cure is a quantitative indicator of the degree of completion of the crosslinking reaction in polymer materials. Offline monitoring of this indicator can ensure that the material meets the preset physical property requirements.

[0090] Specifically, during the curing stage of the surface protective layer, the infrared spectrometer continuously scans the coating flowing on the production line and analyzes the 4000-400cm -1The system calculates the isocyanate group consumption rate in real time by monitoring the intensity changes of characteristic peaks within the wavenumber range. When the monitoring data indicates that the NCO content has fallen below a threshold, the system automatically triggers the curing termination instruction. After completing the online test, samples are randomly selected for differential scanning calorimetry analysis. By comparing the difference in thermal enthalpy between uncured and fully cured samples, the actual degree of cure is accurately calculated. This dual detection mechanism forms a closed-loop control loop, enabling real-time regulation of the production process while ensuring the consistency of final product quality.

[0091] Compared with existing technologies, traditional processes mostly use fixed-time curing or manual sampling inspection, which have problems such as delayed reaction endpoint judgment and low detection coverage. This solution uses online spectral analysis to achieve instant feedback on the chemical reaction process, combined with offline thermal analysis to verify the cross-linking status of the material, and improves the process control accuracy from empirical judgment to a data-driven level. The single detection method in the existing technology cannot take into account both real-time production and reliable results. However, this solution ensures quality compliance while maintaining continuous operation of the production line through the coordinated application of two detection technologies.

[0092] Through the above technical solution, this application effectively solves the problem of coating performance fluctuations caused by inaccurate curing control, so that the adhesion and wear resistance indicators of the surface protective layer are stabilized within the qualified range; at the same time, online detection shortens the process adjustment response time, and offline detection reduces the risk of unqualified products flowing out, and the overall production efficiency is improved by about 20%.

[0093] The above are merely preferred embodiments of the present application and are not intended to limit the present application. Those skilled in the art will readily appreciate that various modifications and variations are possible. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of the present application shall be included within the scope of protection of the present application.

Claims

1. A panel for surface decoration, characterized in that: The invention comprises a texture structure layer, wherein the upper end of the texture structure layer is provided with a surface layer, and the lower end of the texture structure layer is provided with an injection molding structure layer. The texture structure layer is selected from natural rock or imitation natural stone. The natural rock includes at least one of marble, granite and limestone, and has a thickness of 0.3 to 2.0 mm. The imitation natural stone is composited by the following components: stone powder (particle size ≤ 200 mesh) 40 to 70 wt%; resin (epoxy resin or polyester resin) 20 to 50 wt%; non-woven fabric base (gram weight 80 to 150 g / m2) 2 ) 5-15wt%; imitation stone grain additive (at least one of mica powder and metallic glitter powder) 2-8wt%; the surface has natural grain or artificially embossed imitation natural grain, and the grain depth is 0.05-0.5mm; the injection molding structure layer is made of thermoplastic plastic or thermosetting plastic, and is combined with the back of the textured stone layer through the injection molding process; the thermoplastic plastic is selected from at least one of polypropylene (PP), polyethylene (PE), acrylonitrile-butadiene-styrene copolymer (ABS), and polycarbonate (PC), with a thickness of 0.5-3.0mm; the thermosetting plastic is selected from at least one of epoxy resin and phenolic resin, with a thickness of 0.3-2.0mm; injection molding process parameters: melt temperature: 180-280℃ (thermoplastic plastic The surface layer is made of reactive polyurethane (PUR) and is covered on the upper surface of the textured stone layer by injection molding or potting. The PUR components include, by weight: 60-80 parts of polyol (functionality 2-4); 20-40 parts of isocyanate (NCO content 15-30%); 0.1-1.0 parts of catalyst (organic tin or amine); and 1-5 parts of ultraviolet absorber (benzotriazole or benzophenone). The thickness is 0.2-3.0 mm, the surface hardness (pencil hardness) is ≥2H, and the wear resistance (Taber abrasion) is ≤50 mg / 1000 revolutions.

2. The panel for surface decoration according to claim 1, characterized in that: A transition bonding layer is provided between the textured stone layer and the injection molded structural layer, and the transition bonding layer is composed of the following components: 30-50 wt% of ethylene-vinyl acetate copolymer (EVA); 5-15 wt% of silane coupling agent (KH-550 or KH-570); and 30-60 wt% of nano-silicon dioxide (particle size 10-50 nm). The thickness of the transition bonding layer is 0.01-0.1 mm, and interlayer bonding is achieved through a hot pressing process (temperature 100-150° C., pressure 1-5 MPa, time 10-30 s).

3. The panel for surface decoration according to claim 1, characterized in that: Functional particles are added to the surface protection layer, and the functional particles are selected from: thermal conductive particles (at least one of aluminum nitride and aluminum oxide, with a particle size of 1 to 10 μm and an addition amount of 5 to 20 wt%); or antibacterial particles (at least one of silver ion-loaded titanium dioxide and nano-zinc, with an addition amount of 1 to 5 wt%); or self-repairing microcapsules (isocyanate prepolymer microcapsules, with a particle size of 50 to 200 μm and an addition amount of 3 to 10 wt%).

4. The panel for surface decoration according to claim 1, characterized in that: The natural lines or artificially embossed imitation natural lines on the upper surface of the texture structure layer are sprayed with a transparent particle layer.

5. The panel for surface decoration according to claim 1, characterized in that: Reinforcing fibers are added to the injection molding structural layer, and the reinforcing fibers are selected from: glass fibers (short-cut fiber length 3 to 12 mm, addition amount 10 to 30 wt%); or carbon fibers (continuous fiber length 50 to 100 mm, addition amount 5 to 20 wt%); the angle between the fiber orientation direction and the injection molding flow direction is 0 to 45° to improve the tensile strength (≥80 MPa) and flexural modulus (≥3000 MPa) of the material.

6. A process for producing a surface decoration material, characterized in that: The following steps are involved: Step 1: Textured Stone Layer Preparation (1) Natural stone cutting: Select natural stone slabs with a thickness of 0.3 to 2.0 mm and cut them into the target shape by laser cutting or water jet cutting, with the edge chamfer radius ≥ 0.5 mm; (2) Imitation natural stone molding: stone powder, resin, non-woven fabric base and imitation stone grain additives are mixed in proportion, hot pressed (temperature 120-180°C, pressure 5-15 MPa, time 30-120 s), and then the grain is embossed by a texture roller; Step 2: Injection molding of the structural layer (1) Mold design: The depth of the injection mold cavity is 0.5 to 3.0 mm greater than the thickness of the textured stone layer, and a reinforcing rib structure is set on the back (rib height 0.3 to 1.0 mm, spacing 5 to 20 mm); (2) Injection molding parameter setting: adjust the melt temperature, injection pressure and holding time according to the plastic material to ensure that the filling rate is ≥95% and there is no flash; Step 3: Applying surface protection layer (1) PUR injection molding / potting: After mixing the PUR components in proportion, cover the surface of the stone layer through an injection molding machine (screw speed 20-80 rpm) or potting equipment (vacuum degassing treatment); (2) Curing process: Curing at a temperature of 20-40°C and a humidity of 40-70% RH for 4-24 hours, or accelerated curing by infrared radiation (wavelength 800-1200 nm) (time shortened to 1-3 hours).

7. The process for producing a surface decoration material according to claim 5, characterized in that: In the second step, the bonding strength between the injection molding structure layer and the textured stone layer is controlled by the following methods: (1) pretreatment of the back of the stone layer: plasma treatment (power 50-200W, time 30-120s) or chemical etching (hydrofluoric acid solution with a concentration of 5-15%, treatment time 10-60s) is used to increase the surface roughness; (2) mold temperature control: the mold is preheated to 40-80°C before injection molding to reduce the temperature difference stress between the stone layer and the plastic melt.

8. The method for producing a surface decoration material according to claim 5, characterized in that: In step 3, the thickness of the PUR surface protective layer is precisely controlled by: (1) Injection molding process: adopt multi-stage injection speed, the first stage speed is 10-30 mm / s, the second stage speed is 30-80 mm / s, control the flow of the melt front to avoid uneven thickness; (2) Potting process: The PUR component is delivered by a quantitative pump, and the coating thickness is monitored in real time in combination with a laser rangefinder.

9. The method for producing a surface decoration material according to claim 5, characterized in that: In the step 1, the texture imitating natural stone is formed by the following methods: (1) 3D printing texture: using stereolithography 3D printing (SLA) or fused deposition modeling (FDM) to print three-dimensional texture on the surface of the stone powder-resin composite layer, with a layer thickness of 0.05 to 0.2 mm; (2) nanoimprinting texture: using a template with a nano-scale concave-convex structure (period 100 to 500 nm), and transferring the texture by hot pressing (temperature 150 to 200° C., pressure 5 to 10 MPa, time 30 to 60 s).

10. The method for producing a surface decoration material according to claim 5, characterized in that: In step 3, the curing process of the PUR surface protective layer is monitored by the following methods: (1) Online detection: using an infrared spectrometer (wave number range 4000-400 cm -1 ) Real-time monitoring of the NCO group consumption rate, and the curing is determined to be complete when the NCO content is ≤0.5%; (2) Off-line detection: Determine the degree of curing by differential scanning calorimetry (DSC), and the degree of curing is required to be ≥95%.

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