Colored film-coated plate and manufacturing method thereof

Abstract

The invention discloses a colored film-coated plate and a manufacturing method thereof.The colored film-coated plate comprises an iron base plate, at least one side of the base plate is sequentially provided with an adhesive layer, a mirror surface effect layer, a colored resin layer and a protective resin layer, the adhesive layer comprises a first adhesive layer and a second adhesive layer, and the protective resin layer comprises a second adhesive layer and a third adhesive layer. The colored film is of a composite film structure formed by laminating a mirror surface effect layer, a colored resin layer and a protective resin layer in advance, and the colored film is laminated on at least one side of the substrate through gluing of the first adhesive layer and the second adhesive layer. According to the invention, an iron sheet and an iron plate are used as base materials, compared with the traditional substrate which depends on high-price metal plates such as aluminum and stainless steel, the material cost is reduced in a breakthrough manner compared with the aluminum and stainless steel, and the mirror surface effect layer is arranged on the surface of the colored resin layer, so that the product has the effects of high-brightness color development and mirror surface; the problem that the mirror surface effect is difficult to achieve due to the rough surface of the iron base material is solved, and the scene requirements of high-end decoration, advertisement display and the like with strict visual effect requirements are met.

Description

Technical Field

[0001] The present invention relates to the technical field of colored plates, in particular to a colored film-coated plate and a manufacturing method thereof. Background Art

[0002] Demand for high-gloss color-rendering sheet materials continues to rise in the fields of architectural decoration, advertising signage, and industrial manufacturing. Traditional processes often rely on ion spraying, which evenly adheres metallic paint to the substrate surface to impart color and a reflective mirror effect. However, this technology has significant limitations: First, due to the limitations of the metallic paint pigment system, the color gamut is limited. Second, to adapt to the ion spray process, metal sheets such as aluminum and stainless steel that can withstand high temperatures and high pressures and have a smooth, flat surface must be used as carriers. This results in high material costs, severely restricting the product's market competitiveness and application scope.

[0003] With the increasing need for cost control and resource optimization, replacing expensive sheet metal with iron substrates such as iron sheets and plates has become an industry trend. However, the surface of iron substrates naturally has microscopic irregularities and an oxide layer. Directly applying colored pigments to the iron plate using spraying technology will not produce a mirror-like effect. The coating's optical performance is insufficient, and the reflectivity and glossiness fall short of high-end application standards. If traditional colored aluminum film is directly applied for composite lamination, the rough surface of the iron plate will result in significant color differences and visual defects after the film is applied, affecting the product's aesthetics. Summary of the Invention

[0004] The object of the present invention is to provide a colored film-faced board material and a method for manufacturing the same, so as to solve one or more technical problems existing in the prior art and at least provide a beneficial option or create conditions.

[0005] In order to solve the above technical problems, the technical solutions adopted by the present invention are as follows: First, the present invention provides a colored coated board material, including a substrate made of iron, wherein at least one side of the substrate is provided with an adhesive layer, a mirror effect layer, a colored resin layer, and a protective resin layer in sequence along the direction away from the substrate, the adhesive layer includes a first adhesive layer coated on the substrate and a second adhesive layer coated on the colored film, the colored film is a composite film structure pre-laminated with a mirror effect layer, a colored resin layer and a protective resin layer, and the colored film is laminated on at least one side of the substrate by gluing the first adhesive layer and the second adhesive layer.

[0006] The present invention provides a substrate using iron sheets or iron plates. Compared with the traditional reliance on high-priced metal plates such as aluminum and stainless steel (the cost of raw materials accounts for as much as 40%-60% of the total product cost) as a substrate, the material cost is reduced by 30%-50% compared with aluminum and stainless steel, which is a breakthrough in cost reduction. By providing a mirror effect layer on the surface of the colored resin layer, the product has a high-brightness color and a mirror effect, solving the problem that the rough surface of the iron substrate is difficult to achieve a mirror effect, and meeting the needs of high-end decoration, advertising display and other scenes with strict requirements on visual effects.

[0007] As an extension of the above solution: the protective resin layer is provided with a shadowless adhesive layer on a surface of a side away from the substrate.

[0008] In this extended solution, the shadowless adhesive layer further optimizes optical performance, achieving more uniform light reflection and increasing the mirror reflectivity, thereby enhancing the mirror-like reflective effect of the colored laminate. The shadowless adhesive layer, also known as the UV-curing layer, significantly increases its hardness after curing, effectively improving scratch resistance. It also offers excellent weather resistance, effectively protecting the mirror-effect layer and colored resin layer from corrosion in complex outdoor environments such as high temperature, high humidity, and acid and alkali conditions.

[0009] As an extension of the above solution, the colored resin layer is formed by mixing and dispersing color crystals and resin slurry, with the weight of the color crystals representing 0.2%-8% of the resin slurry. By precisely blending the resin slurry and color crystals, the colored resin layer overcomes the color gamut limitations of traditional metallic paints, achieving over 95% of the Pantone color gamut and meeting high-end customized color requirements. Combined with the mirror-like reflective effect of the colored film-coated sheet material, it offers superior visual quality and decorative effects compared to traditional ion spraying processes.

[0010] As an extension of the above solution: the mirror effect layer is an aluminum-plated layer, the aluminum-plated layer is aluminum-plated and molded on the colored resin layer, and the second adhesive layer uses single-component polyurethane as a protective layer for the aluminum-plated layer.

[0011] In this extended solution, after aluminum plating is performed on the colored resin layer, the aluminum layer is susceptible to oxidation, blackening, and scratching. Because the colored film is produced and rolled up in a separate process, the second adhesive layer uses a single-component polyurethane as a temporary protective layer for the aluminum layer, effectively preventing oxidation and scratching. Therefore, the second adhesive layer not only bonds with the first adhesive layer on the iron plate but also effectively protects the aluminum layer.

[0012] In the traditional iron substrate lamination process, due to the significant difference in mechanical properties between the iron substrate and the film layer, wrinkles and warping are very likely to occur at the bending position when the plate is bent. This extended solution, combined with the elastic buffer of the single-component polyurethane adhesive layer, can ensure that the colored laminated plate has no wrinkles or peeling when the bending radius is small (such as R=3mm), thus solving the application defects of the traditional composite process on iron substrates.

[0013] As an extension of the above solution, the colored film comprises, in order: a base film, a release layer, a protective resin layer, a colored resin layer, a mirror effect layer, and a second adhesive layer. The protective resin layer is made of a two-component polyurethane resin or acrylic resin. The protective resin layer effectively protects the colored resin layer and the mirror effect layer, improving the product's wear resistance.

[0014] Secondly, the present invention provides a method for manufacturing a colored film-coated plate material, comprising the following steps: Preparing a colored film of the colored film-covered plate material as described above; Unwinding the iron coil and pre-treating it to obtain a continuous iron plate, wherein the pre-treatment includes unwinding and surface cleaning, leveling and straightening, passivation and drying; The dried iron plate enters the gluing machine, which evenly applies glue on the surface of the iron plate by roller coating, spraying or scraping to form the first adhesive layer. The iron plate after gluing enters the heating box, which uses segmented heating to cure the glue on the iron plate or complete more than 80% of the curing state. A laminating machine is provided at the outlet end of the heating box. The base film of the colored film is peeled off in advance by an automatic film-tearing device before entering the laminating machine. The iron plate after gluing still retains a residual temperature of 60-80°C when it leaves the heating box. At this time, the colored film after peeling off the base film and the iron plate with residual temperature enter the laminating machine synchronously. The heating roller of the laminating machine further heats the iron plate and the composite film to 100-120°C, activating the viscosity of the first adhesive layer of the iron plate and the second adhesive layer of the colored film. Subsequently, the pressing roller of the laminating machine tightly fits the iron plate and the colored film at a pressure of 0.5-1.5MPa. During the continuous rolling process, the residual temperature accelerates the curing of the glue, so that the colored film and the iron plate are firmly bonded to obtain a colored laminated sheet. The colored film-coated sheet material enters the cooling process for cooling treatment. After cooling, the temperature drops to close to room temperature and is transported by the conveyor device to the subsequent process or winding station.

[0015] The colored coated board material provided by the present invention uses iron sheets and iron plates as base materials, and the material cost is 30%-50% lower than that of aluminum and stainless steel; the base film can be better peeled off through the action of the release agent layer, so that the second adhesive layer of the colored film can be effectively bonded with the first adhesive layer with residual heat directly coming out of the heating box. The process shortens the distance from the outlet of the heating box to the laminating machine, reduces heat loss and maintains a higher residual temperature. The single-component polyurethane of the second adhesive layer can use the residual heat of the iron plate to activate the viscosity of the surface, improve the bonding efficiency, and further heat in combination with the laminating machine, fully infiltrate and diffuse, thereby enhancing the bonding force with the glue and ensuring the bonding strength.

[0016] As an extension of the above solution, the segmented heating includes: The entrance of the heating box is the preheating section, and the temperature is set at 40-80℃. The iron plate moves slowly and the time in the preheating section is controlled to be 8-12 minutes. The temperature of the iron plate is slowly increased in the preheating section to promote the full mixing of the components of the first adhesive layer. At the same time, it is avoided that the glue is partially cured prematurely due to excessive temperature, which affects the subsequent cross-linking reaction. Enter the heating section in the middle of the heating box, the temperature is set to 150-220℃, the iron plate moves slowly and the time in the heating section is controlled to be 10-20 minutes, raising the temperature of the iron plate to the optimal curing temperature of the glue; Entering the insulation section at the outlet of the heating box, the temperature is set to 80-100℃, the iron plate moves slowly and the time in the preheating section is controlled to be 10-15 minutes, keeping the temperature stable so that the glue curing reaction continues and further improves the performance of the glue layer.

[0017] In this extended solution, the heating box adopts a stepped temperature change: low temperature in the preheating section, high temperature in the heating section, and medium temperature in the insulation section. This prevents problems such as uneven localized curing and bubbles caused by sudden temperature changes. For example, in the case of two-component polyurethane glue, low temperature at the inlet promotes mixing of the components, high temperature in the middle accelerates the cross-linking reaction, and insulation at the outlet ensures that the curing meets the requirements. Compared with traditional single-temperature curing processes, this improves the curing efficiency of the glue, enhances the cohesion and adhesion of the glue layer, and effectively reduces product defects caused by poor curing.

[0018] As an extension of the above scheme, the pretreatment includes the following steps: Unwinding and surface cleaning: The iron coil is installed on the unwinding machine, and the unwinding speed is controlled by the tension control system to make the iron coil unfold smoothly. The unfolded iron plate then enters the cleaning equipment for cleaning. The cleaned iron plate is transported to the next process by the conveyor device; Leveling and straightening: After cleaning, the iron plate enters the leveling and straightening machine. Through the squeezing and stretching action of multiple sets of rollers, the bending, wave and other shape defects of the iron plate are corrected to make it flat. Passivation and drying: After leveling and straightening, the iron plate enters the passivation tank for passivation treatment, forming a dense passivation film on the surface of the iron plate. After passivation treatment, the iron plate enters the drying equipment, and the moisture on the surface of the iron plate is dried by hot air circulation or infrared heating.

[0019] This extended solution addresses the problem of rough surface of iron substrates by using multi-stage treatment including surface cleaning, leveling and straightening, and passivation to improve the adhesion between the colored film and the iron plate, effectively solving the industry problem of weak bonding between the iron substrate and the film material.

[0020] As an extension of the above scheme, the following steps are also included for curing the shadowless adhesive: After cooling, the colored film-coated sheet material enters the coating equipment, where a layer of shadowless adhesive is evenly coated on the surface of the protective resin layer of the colored film away from the substrate. After coating, the colored film-coated sheet material enters the UV curing equipment, where the shadowless adhesive is rapidly cured by ultraviolet radiation to form a shadowless adhesive layer. The cured colored film-coated sheet material is transported by the conveyor device to the subsequent process or the winding station.

[0021] This extended solution further adds a protective shadowless adhesive layer on the colored film-coated board material. The curing process is completed quickly under ultraviolet light, is less affected by environmental factors (such as temperature and humidity), and has high process stability. As a result, the colored film-coated board material has obvious improvements in optics, protection and other aspects, significantly enhancing the market competitiveness and application value of the product.

[0022] As an extension of the above solution, the steps of preparing the colored film include: Prepare a transparent, high-gloss PET base film with a thickness of 16-19 μm; Silicone oil is used as a release agent and is applied by gravure printing or micro-concave coating process to evenly cover the surface of the base film to form a release agent layer with a thickness of 0.3-0.5μm. After coating, the base film is sent to a drying channel and dried at a temperature of 60-80℃ to fully evaporate the solvent and ensure that the release agent layer is dry and solidified; Use two-component polyurethane resin or acrylic resin as the material of the protective resin layer, and apply it by roller coating or knife coating to make the protective resin evenly cover the surface of the release agent layer. The coating thickness is controlled at 8-12μm. After coating, it cures quickly to form a hard and wear-resistant protective resin layer. The color crystal and the resin slurry are mixed and dispersed to form a colored resin material coated on the protective resin layer, the colored resin is coated on the protective resin layer by knife coating or roller coating, and cured after coating to form a high temperature resistant and uniform colored resin layer; The cured composite film is sent to a vacuum evaporation machine, and aluminum is plated using a resistance heating evaporation source or an electron beam evaporation source. Aluminum vapor is evenly deposited on the surface of the colored resin layer at a deposition rate of 0.5-2nm / s to form an aluminum-plated layer with a mirror effect. A single-component polyurethane is selected as the material for the second adhesive layer, and is applied by roller coating or spraying so that the single-component polyurethane is evenly covered on the surface of the aluminum-plated layer. After coating, the composite film is sent to a moisture curing chamber so that the single-component polyurethane is cross-linked and cured by reacting with moisture in the air to form a strong second adhesive layer. The second adhesive layer is used to bond with the first adhesive layer and also serves as a protective layer for the aluminum-plated layer before being composited with the substrate, isolating the aluminum-plated layer from the external environment and inhibiting oxidation of the aluminum layer.

[0023] This extended solution prepares a colored film through a layered composite method. Through reasonable material selection and process treatment, good adhesion and compatibility are achieved between each layer. The presence of the release agent layer ensures that the performance of the subsequent coating is not affected after the base film is peeled off; the protective resin layer is tightly combined with the colored resin layer and the aluminum-plated layer. The second adhesive layer provides a solid foundation for subsequent lamination and effectively protects the aluminum-plated layer before lamination to prevent the aluminum-plated layer from oxidizing and blackening. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] The present invention will be further described below with reference to the accompanying drawings and embodiments; Figure 1 Schematic diagram of the layered structure of the colored film-coated board material of the embodiment.

[0025] Figure 2 Schematic diagram of the layered structure of the colored film-coated board material of the embodiment having the shadowless adhesive layer.

[0026] Figure 3 Schematic diagram of the layered structure of the colored film of the embodiment.

[0027] In the drawings: 100: substrate, 200: adhesive layer, 210: first adhesive layer, 220: second adhesive layer, 300: mirror effect layer, 400: colored resin layer, 500: protective resin layer, 600: shadowless adhesive layer, 700: release agent layer, 800: base film. DETAILED DESCRIPTION

[0028] This section will describe in detail the specific embodiments of the present invention. The preferred embodiments of the present invention are shown in the accompanying drawings. The purpose of the accompanying drawings is to supplement the description of the text part of the specification with graphics, so that people can intuitively and vividly understand each technical feature and the overall technical solution of the present invention, but it should not be understood as a limitation on the scope of protection of the present invention.

[0029] In the description of the present invention, it should be understood that descriptions involving orientations, such as up, down, front, back, left, right, etc., indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings. They are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation. Therefore, they cannot be understood as limitations on the present invention.

[0030] In the description of the present invention, if there are words such as "several", it means one or more, and "more" means more than two. Greater than, less than, and exceed are understood as not including the number itself, and above, below, and within are understood as including the number itself.

[0031] In the description of the present invention, unless otherwise clearly defined, terms such as setting, installing, and connecting should be understood in a broad sense, and technicians in the relevant technical field can reasonably determine the specific meanings of the above terms in the present invention based on the specific content of the technical solution.

[0032] Reference Figures 1 to 2 , several embodiments of the colored film-covered board material and the manufacturing method thereof of the present invention are given below.

[0033] like Figure 1 As shown, in some embodiments, a colored film-coated board material includes a substrate 100 made of iron. An adhesive layer 200, a mirror effect layer 300, a colored resin layer 400, and a protective resin layer 500 are sequentially provided on at least one side of the substrate 100 in a direction away from the substrate 100. The adhesive layer 200 includes a first adhesive layer 210 applied to the substrate 100 and a second adhesive layer 220 applied to the colored film. The colored film is a composite film structure pre-laminated with the mirror effect layer 300, the colored resin layer 400, and the protective resin layer 500. The colored film is laminated to at least one side of the substrate 100 by gluing the first adhesive layer 210 and the second adhesive layer 220. In some preferred embodiments, the colored film is provided on both sides of the substrate 100, so that both sides of the colored film-coated board material have a bright color and a mirror effect.

[0034] This embodiment uses iron sheets and iron plates as the base material. Compared with the traditional reliance on high-priced metal plates such as aluminum and stainless steel (the raw material cost accounts for as much as 40%-60% of the total product cost) as the base material, the material cost is reduced by 30%-50% compared with aluminum and stainless steel, which is a breakthrough in cost reduction. By providing a mirror effect layer on the surface of the colored resin layer, the product has a high-brightness color and a mirror effect, solving the problem of the difficulty in achieving a mirror effect due to the rough surface of the iron substrate, and meeting the needs of high-end decoration, advertising display and other scenes with strict requirements on visual effects.

[0035] like Figure 2As shown, in some embodiments, the protective resin layer 500 is provided with a shadowless adhesive layer 600 on the side facing away from the substrate 100. This shadowless adhesive layer further optimizes optical performance, provides more uniform light reflection, and increases specular reflectivity, thereby enhancing the specular reflective effect of the colored film-coated sheet material. The shadowless adhesive layer, also known as the UV-curable layer, significantly increases its hardness after curing, effectively improving scratch resistance. It also exhibits excellent weather resistance, effectively protecting the mirror-effect layer and the colored resin layer from corrosion in complex outdoor environments such as high temperature, high humidity, and acid and alkali environments.

[0036] like Figure 1 and Figure 2 As shown, in some embodiments, the colored resin layer 400 is formed by mixing and dispersing color crystals and resin slurry, with the weight of the color crystals representing 0.2%-8% of the resin slurry. By precisely blending the resin slurry and color crystals, the colored resin layer overcomes the color gamut limitations of traditional metallic paints, achieving over 95% Pantone color gamut coverage and meeting high-end customized color requirements. Combined with the mirror-like reflective effect of the colored film-coated sheet material, this provides superior visual quality and decorative effects compared to traditional ion spraying processes.

[0037] In some specific embodiments, detailed production steps for preparing colored resin using resin slurry and color crystals are provided. Commonly used base resins are: , which are selected according to film performance requirements (eg, PMMA for optical films and PU for wear-resistant films). Slurry preparation: Mix resin (epoxy resin, polyurethane, polymethyl methacrylate, polyvinyl alcohol) and diluent (such as acetone, ethyl acetate) at a ratio of 7:3 (weight ratio) and stir until the viscosity is 500-1000 cP (measurable by rotational viscometer) to facilitate subsequent color crystal dispersion. The diluent must be compatible with the resin and have a boiling point ≤80°C (to facilitate subsequent desolventizing). The slurry needs to be filtered (100-200 mesh filter) to remove impurities. Color crystal pretreatment, the color crystal is selected from inorganic color crystals (such as white titanium dioxide, red / yellow iron oxide, black carbon black, etc.); Crushing and refining: Use a jet mill to crush the color crystals to D50 ≤ 5μm (to avoid agglomeration affecting dispersion), or directly purchase nano-grade color crystals; Surface modification: Use silane coupling agent (such as KH-570) at 1-3% of the weight of the color crystal, stir at 60℃ for 30 minutes to enhance compatibility with the resin; Mixing and dispersion: Color depth control: For light-colored films, the amount of color crystals added is controlled to be 0.2-2% of the resin weight; for dark-colored films, the amount of color crystals added is controlled to be 3-8% (exceeding 10% may affect resin curing and film mechanical properties). For example, if 100g of colored resin is prepared and red is required, take 3g of iron oxide color crystals + 97g of resin slurry (containing diluent). Slowly add the color crystals to the resin slurry and stir with an electric stirrer (speed 500-800rpm) for 15 minutes for preliminary dispersion; grind in a horizontal sand mill 2-3 times until the particle size D90 is ≤1μm (detected by a laser particle size analyzer) to avoid color difference on the film surface caused by agglomeration of color crystals; carry out the above steps in a vacuum stirred kettle (vacuum degree -0.08MPa) to prevent oxidation of color crystals such as carbon black and reduce the introduction of bubbles; Vacuum degassing: Pour the mixed liquid into a vacuum degassing machine, maintain a vacuum degree of -0.09MPa, and stir at room temperature for 15-20 minutes until the bubbles disappear completely (observe that there are no bubbles overflowing from the liquid surface); Viscosity fine-tuning: If the viscosity is too high (>1500cP), add 1-2% diluent; if it is too low (<300cP), add a small amount of resin (undiluted). After adjustment, filter again (200 mesh filter) to ensure there are no impurities. like Figure 1 and Figure 2 As shown, in some embodiments, the mirror effect layer 300 is an aluminum-plated layer, and the aluminum-plated layer is aluminum-plated on the colored resin layer 400 , and the second adhesive layer 220 uses a single-component polyurethane as a protective layer for the aluminum-plated layer.

[0038] After aluminum plating on the colored resin layer, the colored film is formed and rolled up in a separate process, so the aluminum layer is susceptible to oxidation, blackening, and scratching. The second adhesive layer uses a single-component polyurethane as a temporary protective layer for the aluminum layer, effectively preventing oxidation and scratching. Therefore, the second adhesive layer not only bonds with the first adhesive layer on the iron plate side, but also effectively protects the aluminum layer.

[0039] In the traditional iron substrate lamination process, due to the significant difference in mechanical properties between the iron substrate and the film layer, wrinkles and warping are very likely to occur at the bending position when the plate is bent. This extended solution, combined with the elastic buffer of the single-component polyurethane adhesive layer, can ensure that the colored laminated plate has no wrinkles or peeling when the bending radius is small (such as R=3mm), thus solving the application defects of the traditional composite process on iron substrates.

[0040] like Figure 3As shown, in some embodiments, the colored film includes, in order: a base film 800, a release layer 700, a protective resin layer 500, a colored resin layer 400, a mirror effect layer 300, and a second adhesive layer 220. The protective resin layer 500 is made of a two-component polyurethane resin or an acrylic resin. The protective resin layer 500 effectively protects the colored resin layer 400 and the mirror effect layer 300, improving the wear resistance of the product.

[0041] In some embodiments, the steps of preparing the colored film include: Prepare a transparent, high-gloss PET base film with a thickness of 16-19 μm. Check the surface of the base film for flatness, scratches, bubbles, and other defects to ensure that the base film quality meets the requirements. Install the qualified PET base film on the unwinding device and adjust the unwinding tension through the tension control system. The tension is controlled at 15-25N to ensure that the base film is unwound smoothly and evenly to avoid deformation or wrinkles caused by uneven tension. Silicone oil is used as a release agent and is applied using a gravure printing or micro-concave coating process. The silicone oil is first diluted to an appropriate viscosity and the solid content is controlled at 1%-3% to ensure a uniform release agent layer with a moderate thickness. The release agent is evenly covered on the surface of the base film to form a release agent layer with a thickness of 0.3-0.5μm. After coating, the base film is sent to a drying channel and dried at a temperature of 60-80℃ to fully evaporate the solvent, ensure that the release agent layer is dry and solidified, enhance the adhesion to the base film, and ensure the coating effect of subsequent coatings; Use two-component polyurethane resin or acrylic resin as the material for the protective resin layer. If two-component polyurethane resin is used, mix the hydroxyl component and isocyanate component at a molar ratio of 1:1.2-1:1.5, add an appropriate amount of solvent to dilute, and adjust the viscosity to 80-120s (coating -4 cups, 25°C). If acrylic resin is used, it can be used directly or add 1%-3% photoinitiator (such as 1173) as needed and adjust the viscosity to 60-100s (coating -4 cups, 25°C). Use roller coating or knife coating to evenly cover the surface of the release agent layer with the protective resin. The coating thickness should be controlled at 8-12μm. After coating, it will cure quickly to form a hard and wear-resistant protective resin layer. If it is a two-component polyurethane resin, after coating, the composite film will be sent to the curing room and cured at 60-80℃ for 15-20 minutes to fully cross-link the resin. If it is an acrylic resin, after coating, it will be immediately put into the UV curing equipment and irradiated with ultraviolet light with a wavelength of 365nm and an intensity of 800-1200mW / cm² for 3-5 seconds to quickly cure the resin and form a hard and wear-resistant protective resin layer. The color crystal and the resin slurry are mixed and dispersed to form a colored resin material coated on the protective resin layer, the colored resin is coated on the protective resin layer by knife coating or roller coating, and cured after coating to form a high temperature resistant and uniform colored resin layer; The cured composite film is sent to the vacuum evaporation machine and aluminum is plated using a resistance heating evaporation source or an electron beam evaporation source. The vacuum chamber is first evacuated to a vacuum degree of ≤10 - ³Pa, then aluminum wire or aluminum pellets with a purity of ≥99.99% are placed in the evaporation source. The evaporation temperature is controlled at 1200-1400°C for resistance heating and 1400-1600°C for electron beam evaporation to fully vaporize the aluminum. Aluminum vapor is evenly deposited on the surface of the colored resin layer at a deposition rate of 0.5-2nm / s. The thickness of the aluminum coating is controlled at 50-200nm, forming a mirror-like aluminum coating. During the aluminum coating process, the composite film conveyor speed is controlled at 3-5m / min, and the vacuum chamber temperature is maintained at 40-60°C to ensure a uniform, dense aluminum coating with excellent mirror-like reflection. A single-component polyurethane is selected as the material for the second adhesive layer, and is applied by roller coating or spraying so that the single-component polyurethane is evenly covered on the surface of the aluminum-plated layer. After coating, the composite film is sent to a moisture curing chamber so that the single-component polyurethane is cross-linked and cured by reacting with moisture in the air to form a strong second adhesive layer. The second adhesive layer is used to bond with the first adhesive layer and also serves as a protective layer for the aluminum-plated layer before being composited with the substrate, isolating the aluminum-plated layer from the external environment and inhibiting oxidation of the aluminum layer.

[0042] This embodiment prepares a colored film by a layered composite method. Good adhesion and compatibility are achieved between each layer through reasonable material selection and process treatment. The presence of the release agent layer ensures that the performance of the subsequent coating is not affected after the base film is peeled off; the protective resin layer is tightly combined with the colored resin layer and the aluminum-plated layer. The second adhesive layer provides a solid foundation for subsequent lamination and effectively protects the aluminum-plated layer before lamination to prevent the aluminum-plated layer from oxidizing and blackening.

[0043] In another aspect, the present invention provides a method for manufacturing a colored film-faced sheet material, comprising the following steps: Prepare a colored film of a colored film-covered plate material as described in the above embodiment; Unwinding the iron coil and pre-treating it to obtain a continuous iron plate, wherein the pre-treatment includes unwinding and surface cleaning, leveling and straightening, passivation and drying; The dried iron plate enters the gluing machine, which evenly applies glue on the surface of the iron plate by roller coating, spraying or scraping to form the first adhesive layer. The iron plate after gluing enters the heating box, which uses segmented heating to cure the glue on the iron plate or complete more than 80% of the curing state. A laminating machine is provided at the outlet end of the heating box. The base film of the colored film is peeled off in advance by an automatic film-tearing device before entering the laminating machine. The iron plate after gluing still retains a residual temperature of 60-80°C when it leaves the heating box. At this time, the colored film after peeling off the base film and the iron plate with residual temperature enter the laminating machine synchronously. The heating roller of the laminating machine further heats the iron plate and the composite film to 100-120°C, activating the viscosity of the first adhesive layer of the iron plate and the second adhesive layer of the colored film. Subsequently, the pressing roller of the laminating machine tightly fits the iron plate and the colored film at a pressure of 0.5-1.5MPa. During the continuous rolling process, the residual temperature accelerates the curing of the glue, so that the colored film and the iron plate are firmly bonded to obtain a colored laminated sheet. The colored film-coated sheet material enters the cooling process for cooling treatment. After cooling, the temperature drops to close to room temperature and is transported by the conveyor device to the subsequent process or winding station.

[0044] The colored coated board material provided by the present invention uses iron sheets and iron plates as base materials, and the material cost is 30%-50% lower than that of aluminum and stainless steel; the base film can be better peeled off through the action of the release agent layer, so that the second adhesive layer of the colored film can be effectively bonded with the first adhesive layer with residual heat directly coming out of the heating box. The process shortens the distance from the outlet of the heating box to the laminating machine, reduces heat loss and maintains a higher residual temperature. The single-component polyurethane of the second adhesive layer can use the residual heat of the iron plate to activate the viscosity of the surface, improve the bonding efficiency, and further heat in combination with the laminating machine, fully infiltrate and diffuse, thereby enhancing the bonding force with the glue and ensuring the bonding strength.

[0045] In some embodiments, the staged heating comprises: The entrance of the heating box is the preheating section, with a temperature set at 40-80°C. The iron plate moves slowly and the time in the preheating section is controlled to be 8-12 minutes. The lower moving speed and longer residence time ensure that the glue is fully preheated in the front section and that the iron plate has enough time to absorb heat in the oven. The temperature of the iron plate is slowly increased in the preheating section to promote the full mixing of the various components of the first adhesive layer and avoid local premature curing of the glue due to excessive temperature, which affects the subsequent cross-linking reaction. Entering the heating section in the middle of the heating box, the temperature is set to 150-220℃. On the basis of the preheating section, the heating speed is appropriately accelerated to quickly reach the optimal curing temperature of the glue and improve production efficiency. The iron plate moves slowly and the time in the heating section is controlled to be 10-20 minutes. The temperature of the iron plate is raised to the optimal curing temperature of the glue. Under the premise of ensuring the curing effect of the glue, the walking speed is appropriately increased to balance production efficiency and curing quality; Entering the insulation section at the outlet of the heating box, the temperature is set to 80-100℃, the iron plate moves slowly and the time in the preheating section is controlled to be 10-15min, keeping the temperature stable, reducing the walking speed, and extending the stay time of the iron plate in the insulation section to ensure that the glue is fully cured, so that the glue curing reaction continues and the performance of the glue layer is further improved.

[0046] In this extended solution, the heating box adopts a stepped temperature change: low temperature in the preheating section, high temperature in the heating section, and medium temperature in the insulation section. This prevents problems such as uneven localized curing and bubbles caused by sudden temperature changes. For example, in the case of two-component polyurethane glue, low temperature at the inlet promotes mixing of the components, high temperature in the middle accelerates the cross-linking reaction, and insulation at the outlet ensures that the curing meets the requirements. Compared with traditional single-temperature curing processes, this improves the curing efficiency of the glue, enhances the cohesion and adhesion of the glue layer, and effectively reduces product defects caused by poor curing.

[0047] In some embodiments, the pre-processing comprises the following steps: Unwinding and surface cleaning: The iron coil is installed on the unwinding machine, and the unwinding speed is controlled by the tension control system to make the iron coil unfold smoothly. The unfolded iron plate then enters the cleaning equipment for cleaning. The cleaned iron plate is transported to the next process by the conveyor device; Leveling and straightening: After cleaning, the iron plate enters the leveling and straightening machine. Through the squeezing and stretching action of multiple sets of rollers, the bending, wave and other shape defects of the iron plate are corrected to make it flat. Passivation and drying: After leveling and straightening, the iron plate enters the passivation tank for passivation treatment, forming a dense passivation film on the surface of the iron plate. After passivation treatment, the iron plate enters the drying equipment, and the moisture on the surface of the iron plate is dried by hot air circulation or infrared heating.

[0048] This extended solution addresses the problem of rough surface of iron substrates by using multi-stage treatment including surface cleaning, leveling and straightening, and passivation to improve the adhesion between the colored film and the iron plate, effectively solving the industry problem of weak bonding between the iron substrate and the film material.

[0049] In some embodiments, the step of curing the shadowless adhesive is further included: After cooling, the colored film-coated sheet material enters the coating equipment, where a layer of shadowless adhesive is evenly coated on the surface of the protective resin layer of the colored film away from the substrate. After coating, the colored film-coated sheet material enters the UV curing equipment, where the shadowless adhesive is rapidly cured by ultraviolet radiation to form a shadowless adhesive layer. The cured colored film-coated sheet material is transported by the conveyor device to the subsequent process or the winding station.

[0050] This extended solution further adds a protective shadowless adhesive layer on the colored film-coated board material. The curing process is completed quickly under ultraviolet light, is less affected by environmental factors (such as temperature and humidity), and has high process stability. As a result, the colored film-coated board material has obvious improvements in optics, protection and other aspects, significantly enhancing the market competitiveness and application value of the product.

[0051] The above specifically describes the preferred embodiments of the present invention, but the invention is not limited to the embodiments. Those skilled in the art may make various equivalent modifications or substitutions without violating the spirit of the present invention. These equivalent modifications or substitutions are all included in the scope defined by the claims of this application.

Claims

1. A colored film-faced sheet material, characterized in that: A substrate (100) made of iron is provided, wherein at least one side of the substrate (100) is provided with an adhesive layer (200), a mirror effect layer (300), a colored resin layer (400), and a protective resin layer (500) in sequence in a direction away from the substrate (100); the adhesive layer (200) comprises a first adhesive layer (210) coated on the substrate (100) and a second adhesive layer (220) coated on a colored film; the colored film is a composite film structure pre-laminated with the mirror effect layer (300), the colored resin layer (400), and the protective resin layer (500); the colored film is laminated on at least one side of the substrate (100) by gluing the first adhesive layer (210) and the second adhesive layer (220).

2. The colored film-faced sheet material according to claim 1, characterized in that: The protective resin layer (500) is provided with a shadowless adhesive layer (600) on a surface of a side away from the substrate (100).

3. The colored film-faced sheet material according to claim 1, characterized in that: The colored resin layer (400) is formed by mixing and dispersing color crystals and resin slurry, and the weight of the color crystals is 0.2%-8% of the resin slurry.

4. The colored film-faced sheet material according to claim 1, characterized in that: The mirror effect layer (300) is an aluminum-plated layer, and the aluminum-plated layer is formed by aluminum plating on the colored resin layer (400). The second adhesive layer (220) uses single-component polyurethane as a protective layer for the aluminum-plated layer.

5. The colored film-faced sheet material according to claim 1, characterized in that: The colored film comprises, in sequence: a base film (800), a release agent layer (700), a protective resin layer (500), a colored resin layer (400), a mirror effect layer (300), and a second adhesive layer (220); the protective resin layer (500) is made of a two-component polyurethane resin or an acrylic resin.

6. A method for manufacturing a colored film-faced sheet material, characterized in that: The following steps are involved: Prepare a colored film of a colored film-faced plate material as described in any one of claims 1 to 5; Unwinding the iron coil and pre-treating it to obtain a continuous iron plate, wherein the pre-treatment includes unwinding and surface cleaning, leveling and straightening, passivation and drying; The iron plate after drying enters the gluing machine, which evenly applies glue on the surface of the iron plate by roller coating, spraying or scraping to form the first adhesive layer. The iron plate after gluing enters the heating box, which uses segmented heating to solidify the glue on the iron plate. A laminating machine is provided at the outlet end of the heating box. The base film (800) of the colored film is peeled off in advance by an automatic film-tearing device before entering the laminating machine. The iron plate after being glued still retains a residual temperature of 60-80°C when leaving the heating box. At this time, the colored film after peeling off the base film (800) and the iron plate with residual temperature enter the laminating machine synchronously. The heating roller of the laminating machine further heats the iron plate and the composite film to 100-120°C, activating the viscosity of the first adhesive layer (210) of the iron plate and the second adhesive layer (220) of the colored film. Subsequently, the pressing roller of the laminating machine tightly fits the iron plate and the colored film at a pressure of 0.5-1.5 MPa. During the continuous rolling process, the residual temperature accelerates the curing of the glue, so that the colored film and the iron plate are firmly bonded to obtain a colored laminated plate. The colored film-coated sheet material enters the cooling process for cooling treatment. After cooling, the temperature drops to close to room temperature and is transported by the conveyor device to the subsequent process or winding station.

7. The method for manufacturing a colored film-faced board material according to claim 6, characterized in that: The segmented heating comprises: The entrance of the heating box is a preheating section, the temperature of which is set at 40-80°C. The iron plate moves slowly and the time in the preheating section is controlled to be 8-12 minutes. The temperature of the iron plate is slowly increased in the preheating section to promote the full mixing of the components of the first adhesive layer (210) and to avoid local premature solidification of the glue due to excessive temperature, which affects the subsequent cross-linking reaction; Enter the heating section in the middle of the heating box, the temperature is set to 150-220℃, the iron plate moves slowly and the time in the heating section is controlled to be 10-20 minutes, raising the temperature of the iron plate to the optimal curing temperature of the glue; Entering the insulation section at the outlet of the heating box, the temperature is set to 80-100℃, the iron plate moves slowly and the time in the preheating section is controlled to be 10-15 minutes, keeping the temperature stable so that the glue curing reaction continues and further improves the performance of the glue layer.

8. The method for manufacturing a colored film-faced board material according to claim 6, characterized in that: The pretreatment comprises the following steps: Unwinding and surface cleaning: The iron coil is installed on the unwinding machine, and the unwinding speed is controlled by the tension control system to make the iron coil unfold smoothly. The unfolded iron plate then enters the cleaning equipment for cleaning. The cleaned iron plate is transported to the next process by the conveyor device; Leveling and straightening: After cleaning, the iron plate enters the leveling and straightening machine. Through the squeezing and stretching action of multiple sets of rollers, the bending, wave and other shape defects of the iron plate are corrected to make it flat. Passivation and drying: After leveling and straightening, the iron plate enters the passivation tank for passivation treatment, forming a dense passivation film on the surface of the iron plate. After passivation treatment, the iron plate enters the drying equipment, and the moisture on the surface of the iron plate is dried by hot air circulation or infrared heating.

9. The method for manufacturing a colored film-faced sheet material according to claim 6, characterized in that: Also includes the shadowless adhesive curing step: After cooling, the colored film-coated board enters a coating device, and a layer of shadowless adhesive is evenly coated on the surface of the protective resin layer of the colored film in the direction away from the substrate (100). After the adhesive is coated, the colored film-coated board enters a UV curing device, and the shadowless adhesive is rapidly cured by ultraviolet radiation to form a shadowless adhesive layer (600); The cured colored film-coated sheet material is transported by the conveyor device to the subsequent process or the winding station.

10. The method for manufacturing a colored film-faced board material according to claim 6, characterized in that: The steps of preparing the colored film include: Preparing a transparent, high-gloss PET base film (800) with a thickness of 16-19 μm; Silicone oil is used as a release agent and is applied by gravure printing or micro-concave coating process so that the release agent is evenly covered on the surface of the base film (800) to form a release agent layer (700) with a thickness of 0.3-0.5 μm. After coating, the base film (800) is sent to a drying channel and dried at a temperature of 60-80° C. to fully volatilize the solvent and ensure that the release agent layer (700) is dried and solidified; A two-component polyurethane resin or acrylic resin is selected as the material of the protective resin layer (500), and the protective resin is applied by roller coating or scraping so that the protective resin is evenly covered on the surface of the release agent layer (700), and the coating thickness is controlled to be 8-12 μm. After coating, the protective resin layer (500) is quickly cured to form a hard and wear-resistant protective resin layer; Mixing color crystals and resin slurry to form a colored resin material to be coated on the protective resin layer (500), coating the colored resin on the protective resin layer (500) by scraping or roller coating, and curing after coating to form a high-temperature resistant and uniformly colored colored resin layer (400); The cured composite film is sent to a vacuum evaporation machine, and aluminum is plated using a resistance heating evaporation source or an electron beam evaporation source. Aluminum vapor is evenly deposited on the surface of the colored resin layer at a deposition rate of 0.5-2nm / s to form an aluminum-plated layer with a mirror effect. A single-component polyurethane is selected as the material of the second adhesive layer (220), and is applied by roller coating or spraying so that the single-component polyurethane is evenly covered on the surface of the aluminum-plated layer. After coating, the composite film is sent to a moisture curing chamber so that the single-component polyurethane is cross-linked and cured by reacting with moisture in the air to form a strong second adhesive layer (220). The second adhesive layer (220) is used for bonding with the first adhesive layer (210) and also serves as a protective layer for the aluminum-plated layer before being composited on the substrate (100), isolating the aluminum-plated layer from the external environment and inhibiting oxidation of the aluminum layer.

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