Production process of functional composite decorative wallboard

Abstract

The invention discloses a production process of a functional composite decorative wallboard, the functional composite decorative wallboard comprises a surface layer, a reinforcing layer, a backing layer and a base material layer, the base material layer is made of a wood-plastic composite board, the backing layer is made of a glass fabric, the reinforcing layer is made of a polyethylene film and an antibacterial agent coating, and the antibacterial agent coating is made of an antibacterial agent. The surface layer is prepared from a UV curing coating and a natural stone slice; the wood-plastic composite board comprises wood fibers, polyvinyl chloride, a compatilizer and a lubricant, the glass fabric is alkali-free glass fabric; the antibacterial agent coating comprises an inorganic antibacterial agent, water-based acrylic resin and a dispersing agent. The invention relates to the technical field of wallboards. The polyethylene film in the reinforcing layer forms a reliable moisture-proof barrier, and the silver-loaded zeolite antibacterial coating is matched, so that moisture permeation is effectively blocked, bacterium breeding is inhibited, and the defect that a wooden or common wood-plastic wallboard is prone to being damped and mildewed is overcome.

Description

Technical Field

[0001] This invention relates to the field of wall panel technology, and more specifically to a production process for a functional composite decorative wall panel. Background Technology

[0002] With the development of the building decoration industry, the market demand for decorative wall panels has shifted from simple decoration to a composite of "decoration + function + environmental protection". Traditional wooden wall panels, although of good texture, are easily affected by humid environments and are prone to deformation and mold. They also rely on natural wood resources and are not environmentally friendly enough. Natural stone wall panels are highly decorative but are heavy, brittle, and have high installation and transportation costs. They also lack antibacterial functions. Ordinary wood-plastic wall panels are environmentally friendly, but their poor material compatibility leads to insufficient strength, and their decorative features are limited, making it difficult to meet the needs of high-end scenarios.

[0003] Existing composite wall panels often suffer from problems such as limited functionality, weak interlayer bonding, and performance imbalance, such as easy coating peeling and difficulty in balancing strength and environmental friendliness in the substrate. Summary of the Invention

[0004] To solve the above-mentioned technical problems, the present invention provides a functional composite decorative wall panel, comprising a surface layer, a reinforcing layer, a backing layer and a substrate layer, wherein the substrate layer is made of wood-plastic composite board, the backing layer is made of fiberglass cloth, the reinforcing layer is made of polyethylene film and antibacterial coating, and the surface layer is made of UV-cured coating and natural stone flakes. The wood-plastic composite board includes wood fibers, polyvinyl chloride, compatibilizer, and lubricant; The fiberglass cloth is made of alkali-free fiberglass cloth. The antibacterial coating comprises an inorganic antibacterial agent, an aqueous acrylic resin, and a dispersant.

[0005] A manufacturing process for a functional composite decorative wall panel includes the following steps: Step 1: Crush and clean the wood fiber and polyvinyl chloride to remove impurities, mix them with compatibilizer and lubricant according to the formula, plasticize the mixture through a twin-screw extruder, extrude it through a plate die, and then vacuum sizing and water cooling to shape it into a substrate board; Step 2: Sand the front and back of the substrate board to remove surface burrs. Cut the alkali-free fiberglass cloth to the same width as the substrate board. Activate the surface of the alkali-free fiberglass cloth through plasma treatment. Apply water-based epoxy adhesive to the back of the substrate using a roller coater. Lay the treated fiberglass cloth flat on the adhesive surface and press it together using a cold press. Let it dry naturally until the adhesive is cured. Step 3: The polyethylene film is treated with corona discharge. The inorganic antibacterial agent is mixed with water-based acrylic resin and dispersant in a certain proportion and stirred until uniformly dispersed to form an antibacterial agent coating. The antibacterial agent coating is applied to the surface of the polyethylene film by a scraper and then dried and cured by a hot air dryer to form a reinforcing layer. Step 4: Apply hot melt adhesive to the front side of the substrate and heat-press the reinforcing layer together; Step 5: Select natural stone, cut it, polish it with a water grinder until the surface is smooth, then process it into thin sheets of the same size as the substrate using a cutting machine. Finally, clean it with deionized water to remove surface dust, dry it with hot air, apply modified silicone adhesive to the surface of the antibacterial coating of the reinforcing layer, align and lay the natural stone sheets, roll them with a roller press to remove air bubbles, and let them stand to cure. Step 6: Select UV-curable acrylic resin, add photoinitiator, wear-resistant filler, and leveling agent, stir evenly and filter, apply to the surface of natural stone flakes by spray coating or roller coating, and cure by UV curing machine. Step 7: Cut the composite board to standard size using a CNC cutting machine, and chamfer the edges with a sander to obtain the composite decorative wall panel.

[0006] Furthermore, the compatibilizer is maleic anhydride-grafted polyethylene, the lubricant is zinc stearate, and the mass ratio of polyvinyl chloride, plant fiber, compatibilizer and lubricant is 20:50:3:3.

[0007] Furthermore, the temperature of the twin-screw extruder is set to 160-200℃, the screw speed is set to 30-60 r / min, the negative pressure of the vacuum sizing is set to 0.05-0.08 MPa, and the water temperature of the water-cooled shaping is set to 20-30℃.

[0008] Furthermore, the alkali-free fiberglass cloth is 200-300g / ㎡, the plasma treatment power is set to 500-800W, the treatment time is set to 10-20s, the solid content of the water-based epoxy adhesive is set to 40%-50%, and the coating amount is set to 80-120g / ㎡.

[0009] Furthermore, the cold press pressure is set to 0.3-0.5 MPa, the time is set to 3-5 min, the natural drying temperature is set to 60-80℃, and the time is set to 30-60 min.

[0010] Furthermore, the inorganic antibacterial agent is silver-loaded zeolite, the dispersant is sodium polycarboxylate, the mass ratio of the inorganic antibacterial agent, water-based acrylic resin and dispersant is 30:5:0.4, the dry film thickness of the antibacterial agent coating is set to 5-10 μm, the temperature of the hot air dryer is set to 80-100℃, and the time is set to 2-3 min.

[0011] Furthermore, the hot melt adhesive is EVA hot melt adhesive, the melting temperature is set to 120-140℃, the coating amount is set to 100-150g / ㎡, the hot pressing bonding temperature is set to 100-120℃, the pressure is set to 0.4-0.6MPa, and the time is set to 1-2min.

[0012] Furthermore, the pressure of the roller press is set to 0.2-0.3 MPa, the speed is set to 1-2 m / min, the static curing temperature is set to 25℃, and the time is set to 24 h.

[0013] Furthermore, the wavelength of the UV curing machine is set to 365nm, the light intensity is set to 80-120mW / cm², and the curing time is set to 3-5s.

[0014] This invention provides a manufacturing process for a functional composite decorative wall panel. It offers the following advantages: 1. The combination of natural stone flakes and UV-cured coating not only retains the high-end decorative texture of natural stone, but also achieves surface wear resistance, stain resistance and UV aging resistance by taking advantage of the high hardness and weather resistance of the UV coating.

[0015] 2. The polyethylene film in the reinforcing layer forms a reliable moisture barrier, which, combined with the silver-loaded zeolite antibacterial coating, effectively blocks moisture penetration and inhibits bacterial growth, overcoming the defects of wood or ordinary wood-plastic wall panels that are prone to moisture and mold. 3. In terms of structural performance, the base material layer uses wood-plastic composite board, and the interfacial bonding force is improved by compatibilizer. Combined with the reinforcing effect of fiberglass cloth backing, the flexural strength of the wall panel is increased by more than 30%, and the deformation resistance is significantly enhanced.

[0016] 4. Plasma treatment of fiberglass cloth and corona treatment of polyethylene film enhance bonding strength, ensuring an interlayer peel strength ≥0.6MPa and preventing delamination. Simultaneously, the entire structure utilizes formaldehyde-free adhesives and recyclable raw materials, meeting green environmental standards, and its lightweight design adapts to the decorative and functional needs of various architectural scenarios. Detailed Implementation

[0017] The following detailed description of specific embodiments further illustrates the present invention. The embodiments of the present invention are given for illustrative and descriptive purposes only and are not intended to be exhaustive or to limit the invention to the disclosed forms. Many modifications and variations will be apparent to those skilled in the art. The embodiments were chosen and described to better illustrate the principles and practical application of the invention, and to enable those skilled in the art to understand the invention and design various embodiments with various modifications suitable for a particular purpose.

[0018] Example, substrate layer preparation: Polyvinyl chloride, wood fiber, maleic anhydride-grafted polyethylene (compatibilizer), and zinc stearate (lubricant) are taken in a mass ratio of 20:50:3:3. The wood fiber and polyvinyl chloride are crushed, cleaned, and impurity removed, and then mixed with the compatibilizer and lubricant. The mixture is added to a twin-screw extruder (temperature 160-200℃, screw speed 30-60r / min) for plasticization. After extrusion through a plate die, the substrate board is formed by vacuum sizing (negative pressure 0.05-0.08MPa) and water cooling (water temperature 20-30℃).

[0019] Backing layer lamination: Sand the front and back of the substrate to remove burrs. Select 200-300g / ㎡ alkali-free fiberglass cloth, cut to the same width as the substrate, and activate the surface with 500-800W plasma treatment for 10-20s. Apply a 40%-50% solids content water-based epoxy adhesive (80-120g / ㎡) to the back of the substrate using a roller coater. Lay the treated fiberglass cloth on top, press it together with a cold press (pressure 0.3-0.5MPa, time 3-5min), and allow it to air dry (60-80℃, 30-60min) until the adhesive is cured.

[0020] Reinforcing layer preparation and lamination: The polyethylene film is corona-treated. An inorganic antibacterial agent (silver-loaded zeolite), water-based acrylic resin, and dispersant (sodium polycarboxylate) are mixed at a mass ratio of 30:5:0.4 and stirred until uniformly dispersed to form an antibacterial coating. The antibacterial coating (dry film thickness 5-10 μm) is applied to the surface of the polyethylene film using a scraper and dried and cured in a hot air dryer (80-100℃, 2-3 min) to form the reinforcing layer. EVA hot melt adhesive (melting temperature 120-140℃, coating amount 100-150 g / ㎡) is applied to the front side of the substrate. The reinforcing layer is then hot-pressed together (temperature 100-120℃, pressure 0.4-0.6 MPa, time 1-2 min).

[0021] Surface layer lamination: Natural stone is selected, cut and polished with a water grinder until the surface is smooth, and cut into thin sheets of the same size as the substrate. After cleaning with deionized water, it is dried with hot air. Modified silicone adhesive is applied to the antibacterial coating surface of the reinforcing layer, and the natural stone sheets are aligned and laid on top. Air bubbles are removed by rolling with a roller press (pressure 0.2-0.3MPa, speed 1-2m / min), and it is left to cure at 25℃ for 24 hours.

[0022] UV coating curing: Take UV-curable acrylic resin, add photoinitiator, wear-resistant filler and leveling agent, stir evenly and filter, then coat or roll it on the surface of natural stone flakes, and cure by irradiation with a UV curing machine (wavelength 365nm, light intensity 80-120mW / cm²) for 3-5 seconds.

[0023] Post-processing: The composite board is cut to standard size using a CNC cutting machine, and the edges are beveled with a sander to obtain a functional composite decorative wall panel. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of them. All other embodiments obtained by those skilled in the art and related fields based on the embodiments of the present invention without inventive effort should fall within the scope of protection of the present invention. Structures, devices, and operating methods not specifically described and explained in the present invention, unless otherwise specified or limited, shall be implemented according to conventional means in the art.

Claims

1. A functional composite decorative wall panel, characterized in that: It includes a surface layer, a reinforcing layer, a backing layer, and a substrate layer, wherein the substrate layer is made of wood-plastic composite board, the backing layer is made of fiberglass cloth, the reinforcing layer is made of polyethylene film and antibacterial coating, and the surface layer is made of UV-cured coating and natural stone flakes; The wood-plastic composite board includes wood fibers, polyvinyl chloride, compatibilizer, and lubricant; The fiberglass cloth is made of alkali-free fiberglass cloth. The antibacterial coating comprises an inorganic antibacterial agent, an aqueous acrylic resin, and a dispersant.

2. The production process of a functional composite decorative wall panel according to claim 1, characterized in that: Includes the following steps: Step 1: Crush and clean the wood fiber and polyvinyl chloride to remove impurities, mix them with compatibilizer and lubricant according to the formula, plasticize the mixture through a twin-screw extruder, extrude it through a plate die, and then vacuum sizing and water cooling to shape it into a substrate board; Step 2: Sand the front and back of the substrate board to remove surface burrs. Cut the alkali-free fiberglass cloth to the same width as the substrate board. Activate the surface of the alkali-free fiberglass cloth through plasma treatment. Apply water-based epoxy adhesive to the back of the substrate using a roller coater. Lay the treated fiberglass cloth flat on the adhesive surface and press it together using a cold press. Let it dry naturally until the adhesive is cured. Step 3: The polyethylene film is treated with corona discharge. The inorganic antibacterial agent is mixed with water-based acrylic resin and dispersant in a certain proportion and stirred until uniformly dispersed to form an antibacterial agent coating. The antibacterial agent coating is applied to the surface of the polyethylene film by a scraper and then dried and cured by a hot air dryer to form a reinforcing layer. Step 4: Apply hot melt adhesive to the front side of the substrate and heat-press the reinforcing layer together; Step 5: Select natural stone, cut it, polish it with a water grinder until the surface is smooth, then process it into thin sheets of the same size as the substrate using a cutting machine. Finally, clean it with deionized water to remove surface dust, dry it with hot air, apply modified silicone adhesive to the surface of the antibacterial coating of the reinforcing layer, align and lay the natural stone sheets, roll them with a roller press to remove air bubbles, and let them stand to cure. Step 6: Select UV-curable acrylic resin, add photoinitiator, wear-resistant filler, and leveling agent, stir evenly and filter, apply to the surface of natural stone flakes by spray coating or roller coating, and cure by UV curing machine. Step 7: Cut the composite board to standard size using a CNC cutting machine, and chamfer the edges with a sander to obtain the composite decorative wall panel.

3. The functional composite decorative wall panel according to claim 2, characterized in that: The compatibilizer is maleic anhydride-grafted polyethylene, the lubricant is zinc stearate, and the mass ratio of polyvinyl chloride, plant fiber, compatibilizer and lubricant is 20:50:3:

3.

4. A functional composite decorative wall panel according to claim 2, characterized in that: The temperature of the twin-screw extruder is set to 160-200℃, the screw speed is set to 30-60 r / min, the negative pressure of the vacuum sizing is set to 0.05-0.08 MPa, and the water temperature of the water-cooled shaping is set to 20-30℃.

5. A functional composite decorative wall panel according to claim 2, characterized in that: The alkali-free fiberglass cloth is 200-300g / ㎡, the plasma treatment power is set to 500-800W, the treatment time is set to 10-20s, the solid content of the water-based epoxy adhesive is set to 40%-50%, and the coating amount is set to 80-120g / ㎡.

6. A functional composite decorative wall panel according to claim 2, characterized in that: The cold press pressure is set to 0.3-0.5 MPa, and the time is set to 3-5 min. The natural drying temperature is set to 60-80℃, and the time is set to 30-60 min.

7. A functional composite decorative wall panel according to claim 2, characterized in that: The inorganic antibacterial agent is silver-loaded zeolite, the dispersant is sodium polycarboxylate, the mass ratio of the inorganic antibacterial agent, water-based acrylic resin and dispersant is 30:5:0.4, the dry film thickness of the antibacterial agent coating is set to 5-10 μm, the temperature of the hot air dryer is set to 80-100℃, and the time is set to 2-3 min.

8. A functional composite decorative wall panel according to claim 2, characterized in that: The hot melt adhesive used is EVA hot melt adhesive, with a melting temperature of 120-140℃ and a coating amount of 100-150g / ㎡. The hot pressing bonding temperature is set to 100-120℃, the pressure is set to 0.4-0.6MPa, and the time is set to 1-2min.

9. A functional composite decorative wall panel according to claim 2, characterized in that: The roller press pressure is set to 0.2-0.3 MPa, the speed is set to 1-2 m / min, the static curing temperature is set to 25℃, and the time is set to 24 h.

10. A functional composite decorative wall panel according to claim 2, characterized in that: The wavelength of the UV curing machine is set to 365nm, the light intensity is set to 80-120mW / cm², and the curing time is set to 3-5s.