3D wood textured stone-plastic floor and preparation method therefor

Abstract

The present invention relates to the technical field of wood floor manufacturing, and in particular to a 3D wood textured stone-plastic floor and a preparation method therefor. The present invention improves surface roughness of a ground color layer by means of causing the surface of the ground color layer over an SPC substrate to be provided with irregularly distributed holes. In addition, paint of a three-dimensional wood grain layer located above the ground color layer enters from the holes and permeates downwards, so that the adhesive force between the SPC base material layer and the three-dimensional wood grain layer located over the SPC base material layer is enhanced, and bonding is more stable. The surface roughness of the ground color layer is increased by means of performing high-energy beam stimulation treatment on the surface of the ground color layer. In addition, molecules on the surface of the ground color layer are oxidized to produce groups having strong polarity, thereby increasing the surface energy thereof and making it easy for the molecules to bond with the paint used to print the three-dimensional wood grain layer, effectively improving the wettability and adhesiveness of the surface of the ground color layer. Furthermore, the warpage of the three-dimensional wood grain layer is effectively reduced, the decorative effect of the three-dimensional wood grain layer is improved, and the product quality of the stone plastic floor is ensured.

Description

Stone-plastic floor with 3D wood texture and preparation method thereof Technical Field

[0001] The invention belongs to the technical field of wood floor manufacturing, and particularly relates to a stone-plastic floor with 3D wood texture and a preparation method thereof. Background Art

[0002] Wood flooring primarily includes solid wood flooring, laminate flooring, and engineered wood flooring. Solid wood flooring has a natural grain, offering a natural, soft, and inviting feel. It's also warm in winter and cool in summer, and pleasant to the touch. However, using large quantities of solid wood flooring consumes a lot of wood, resulting in high costs and potentially causing serious damage to the environment. Engineered wood flooring, made by interlacing and laminating planks of different tree species, overcomes the shortcomings of solid wood flooring, which tends to swell and shrink when wet, offering lower shrinkage and better dimensional stability. It also retains the natural wood grain and comfortable feel of solid wood flooring. However, engineered wood flooring has a complex structure and requires sophisticated production processes. Furthermore, its grain pattern is not wear-resistant and easily fades. Water damage is irreparable, resulting in high costs. Furthermore, the production of engineered wood flooring requires glue, which can easily release harmful gases such as formaldehyde, posing potential health risks.

[0003] Laminate flooring is made of one or more layers of specialized paper impregnated with thermosetting amino resin, applied to the surface of a wood-based panel such as particleboard or high-density fiberboard. A balanced moisture-proof layer is added to the back, and a wear-resistant and decorative layer is added to the front. The flooring is then hot-pressed and formed. Laminate flooring offers excellent resistance to pollution, corrosion, compression, wear, impact, and flame retardancy, as well as good stability, ease of care, and low cost. Laminate flooring is typically decorated by affixing printed paper to its surface, but this paper can easily fall off and become damaged, and the texture lacks fidelity, resulting in poor simulation and decorative effects. The affixed wear-resistant paper can easily become detached from the flooring substrate due to footsteps and vibrations during use, reducing the wood floor's service life and diminishing its quality and grade.

[0004] With the advancement of science and technology, plastics are increasingly being used in our daily lives. Stone plastic flooring, primarily made of PVC, is gaining popularity among consumers. Stone plastic flooring (also known as PVC sheet flooring) is a new type of flooring material. It utilizes a high-density, high-fiber mesh structure to create a solid base layer of stone powder, covered with a highly wear-resistant polymer PVC wear-resistant layer. Stone plastic flooring offers excellent properties such as environmental friendliness, exceptional wear resistance, waterproofness, moisture resistance, fire retardancy, and recyclability. It comes in a wide variety of patterns and colors, with realistic and beautiful patterns. It can simulate a variety of natural or artificial patterns, fully satisfying personalized design needs. It is highly popular in developed European and American countries and the Asia-Pacific market.

[0005] With the exception of solid wood floors, which have a natural grain, all other types of flooring require a printed pattern on the substrate, followed by a surface treatment such as varnishing to achieve wear and scratch resistance. However, the surface decorative wood grain achieved through this method is a flat pattern, lacking the visual impact of real wood grain. Furthermore, the surface decorative wood grain feels rough and unnoticeable, appearing rigid and lacking the sense of wood. Therefore, when reproducing the texture of wood on a stone-plastic composite flooring substrate (SPC), in addition to reproducing the flat color pattern, it is necessary to also create a three-dimensional wood grain structure with a rich, concave and convex texture on the SPC surface. This creates a three-dimensional wood grain effect more similar to the feel of natural wood, further resulting in a SPC floor with a fine, realistic, tactile, comfortable, and three-dimensional wood texture. However, during the development of the manufacturing process for SPC flooring with a 3D wood texture, developers discovered that SPC flooring with a 3D wood texture is prone to warping, deformation, and peeling due to thermal expansion and contraction in high or low temperature environments. Furthermore, prolonged exposure to uneven temperatures can lead to uneven moisture loss within the SPC flooring, causing deformation. Furthermore, when installing SPC flooring indoors, the SPC substrate layer and the three-dimensional wood grain layer above the SPC substrate layer can differ in thickness. The SPC substrate layer can absorb excessive moisture, causing tile-like warping and buckling. This can even lead to the three-dimensional wood grain layer peeling off from the SPC substrate layer, seriously impacting the lifespan and aesthetics of the 3D wood-textured SPC flooring.

[0006] The reason is that the 3D wood-grained SPC flooring has a multi-layered structure, resulting in an excessively thick layer of paint applied to the SPC substrate to create the 3D wood-grain layer. The production process is complex, and even after multiple rounds of roller pressing, some internal stress persists within the SPC flooring, which cannot be completely eliminated. Furthermore, digitally printed 3D wood-grained SPC flooring is ultra-light and thin, measuring only 2-3mm thick and weighing only 2-3kg per square meter, less than 10% of ordinary flooring materials. 3D wood-grained SPC flooring also features a solid base layer composed of a high-density, high-fiber mesh structure of stone powder, resulting in exceptional hardness. However, the 3D wood-grained layer above the SPC substrate has different shrinkage rates than the SPC substrate itself. As the liquid paint solidifies to form the 3D wood-grained layer, its volume shrinks. As the paint is applied layer by layer onto the SPC substrate, this shrinkage force increases, causing the 3D wood-grained layer to wrinkle and deform more noticeably. Excessive warping can lead to convex deformation of the 3D wood-grained layer. If the warping is more serious, the adhesion between the SPC substrate and the three-dimensional wood grain layer will decrease, further causing the SPC substrate layer to peel off from the three-dimensional wood grain layer above it.

[0007] To this end, researchers have minimized the number of paint layers applied to the SPC substrate surface. A thinner paint coating can easily blur the pattern, obscure the wood grain, and easily wear out the three-dimensional wood grain layer, resulting in a poor decorative effect. Researchers have also minimized the difference in shrinkage between the SPC substrate and the three-dimensional wood grain layer to prevent warping and wrinkling in the three-dimensional wood grain layer. For example, patent CN101629446A provides a printed flooring and its production method. A first coating layer is applied to the surface of the flooring substrate, covered with a printed pattern layer. A second coating layer is applied over the printed pattern layer, and a topcoat layer is applied over the second coating layer. Both the first and second coating layers are shrinkage-resistant paint layers formed from a flexible polymer composition. This problem of shrinkage differences between the substrate and the pattern layer is addressed by applying a layer of shrinkage-resistant paint made from a flexible polymer composition before printing the pattern. However, the flexible polymer composition exhibits a certain degree of plasticity after film formation, and can undergo some stretching or compression under external forces. This can cause inaccurate application of the ink used to form the pattern layer above it, further leading to significant variations in the resulting pattern.

[0008] In addition, researchers have attempted to directly improve the performance of the SPC substrate to obtain a stone plastic floor with not only better mechanical properties but also lower dimensional deformation rate. For example, patent CN111792876A provides an SPC stone plastic floor material and its floor, which discloses an SPC stone plastic floor material, including: 100 parts by weight of PVC resin; 220-260 parts by weight of heavy calcium carbonate; 40-80 parts by weight of nano calcium carbonate; 2-4 parts by weight of stearic acid; 8-12 parts by weight of impact modifier; and 4-8 parts by weight of masterbatch. The raw materials of the masterbatch are composed of PVC resin, EVA wax, CI Pigment Yellow 139, a composite dispersant, and other optional additives; wherein the composite dispersant is selected from propylene pimaric acid grafted poly-(12-hydroxystearic acid) and lauric acid diethanolamide. However, the poor diffusion and miscibility of the dispersant or additives used in the masterbatch can easily cause the formed SPC substrate to become brittle and crack, affecting the quality of the stone plastic floor. At the same time, the masterbatch contains CI Pigment Yellow 139, which is prone to pigment migration, causing the prepared SPC substrate to have obvious color development, further leading to large color differences when the pattern is subsequently printed on the SPC substrate, affecting the appearance of the stone plastic floor.

[0009] Furthermore, researchers are continuously improving the performance of paint coatings that cure to form a three-dimensional wood grain layer, aiming to develop a UV-curable coating that offers strong adhesion, excellent wear resistance, environmental friendliness, a soft gloss, and high hardness to meet diverse market demands. For example, patent CN115558401A provides a high-strength UV-curable coating for SPC flooring and a method for its preparation. The coating is prepared by adding an acrylic compound, a photoinitiator, and a solvent to a container, mixing and stirring, and then adding a matting agent and stirring. However, this UV-curable coating has a high viscosity, which can easily cause "stringing" and surface roughness during spraying. Furthermore, its low solids content makes it difficult to achieve a balanced combination of hardness and elasticity. This makes it difficult to achieve a very thick coating film in a single spray application, and the film's fullness is less than ideal.

[0010] Therefore, researchers hope to find a new method to prevent the three-dimensional wood grain layer in stone plastic flooring with 3D wood texture from warping and deformation, or even causing it to peel off from the SPC substrate layer. This method is efficient, easy to operate and has low application cost. However, this problem has not been solved. Summary of the Invention

[0011] The present invention aims to overcome the defect in the prior art of preparing a stone-plastic floor with 3D wood texture that the three-dimensional wood grain layer contained therein is easily warped, causing the stone-plastic floor to convexly deform, and provides a stone-plastic floor with 3D wood texture and a preparation method thereof.

[0012] According to one aspect of the present invention, the applicant has discovered a method for manufacturing a stone-plastic floor with a 3D wood texture by treating the surface of an SPC substrate layer.

[0013] According to the first aspect, in order to achieve the above-mentioned object of the invention, the present invention is implemented through the following technical solutions:

[0014] A method for manufacturing a stone-plastic floor with a 3D wood texture, comprising at least the following steps:

[0015] (S.1) a step of extruding to obtain a stone plastic floor substrate;

[0016] (S.2) The step of covering the surface of the stone plastic floor substrate with a base color layer;

[0017] (S.3) a step of imparting irregularly distributed holes to the surface of the base color layer;

[0018] (S.4) a step of exciting the surface of the base color layer obtained in the previous step with a high energy beam;

[0019] (S.5) coating at least a portion of the surface of the base color layer obtained in the previous step with a primer, and curing the primer to obtain a primer layer;

[0020] (S.6) The step of forming a color paint layer, a pattern layer, a three-dimensional wood grain layer, and a top paint layer in sequence from bottom to top on at least a portion of the surface of the primer layer.

[0021] Preferably, the process of obtaining the base color layer in step (S.2) includes:

[0022] The step of covering the surface of the stone plastic floor substrate with a base color film.

[0023] Preferably, the base color layer comprises at least one or more combinations of polyvinyl chloride resin, colorant, plasticizer, heat stabilizer, and lubricant.

[0024] Preferably, the base color layer is white and has a thickness of 0.05-0.15 mm.

[0025] Preferably, the process of providing irregularly distributed holes on the surface of the base color layer in step (S.3) includes:

[0026] The step of making the surface of the base color layer contact with the grinding tool and thus be polished.

[0027] Preferably, the surface roughness Ra value of the base color layer after contacting the grinding tool is 0.3-1.6 μm.

[0028] Preferably, the grinding tool is any one of a belt machine, a belt grinder, and a belt polisher.

[0029] Preferably, the abrasive tool comprises a combination of one or more of abrasive belts, sandpaper, and gauze.

[0030] Preferably, the process of subjecting the surface of the base color layer to high energy beam stimulation in step (S.4) includes:

[0031] The step of subjecting the surface of the base color layer to high-frequency high-voltage corona discharge.

[0032] Preferably, the current of the high-frequency high-voltage corona discharge is 4-8A.

[0033] Preferably, the surface tension of the base color layer after being stimulated by the high-energy beam is 36-40 mN / m.

[0034] Preferably, the surface of the base color layer is subjected to high-frequency and high-voltage corona discharge at a rate of 15 to 30 m / min.

[0035] Preferably, the distance between the surface of the base color layer and the discharge electrode applying high-frequency high-voltage electricity is 2 to 5 cm.

[0036] Preferably, the primer in step (S.5) comprises at least a photo-crosslinking resin and a photoinitiator.

[0037] Preferably, the photo-crosslinking resin includes any one or more combinations of unsaturated polyester, epoxy resin, acrylic resin, acrylic modified polyurethane resin, acrylic modified silicone resin, acrylic modified epoxy resin, water-based epoxy acrylate, water-based polyurethane acrylate, and water-based polyester acrylate.

[0038] Preferably, the photoinitiator includes any one of a free radical polymerization initiator, a cationic polymerization initiator, an energy transfer initiator, and an ion reaction initiator.

[0039] Preferably, the amount of primer applied to the surface of the base color layer in step (S.5) is 10-15 g / m 2 .

[0040] Preferably, the color paint layer in step (S.6) is white, and the amount of the color paint in the color paint layer is 15-25 g / m 2 .

[0041] Preferably, the process of forming the pattern layer in step (S.6) includes:

[0042] The step of coating at least a portion of the surface of the color paint layer with ink for forming a wood grain pattern and curing the ink to obtain a pattern layer.

[0043] Preferably, the amount of ink used in the pattern layer in step (S.6) is 6-10 g / m 2 .

[0044] Preferably, the process of forming the three-dimensional wood grain layer in step (S.6) includes:

[0045] The step of covering at least a portion of the surface of the pattern layer with a three-dimensional wood grain layer having a three-dimensional structure.

[0046] Preferably, the process of forming the topcoat layer in step (S.6) includes:

[0047] The step of coating at least a portion of the surface of the three-dimensional wood grain layer with a topcoat and curing the topcoat layer.

[0048] Preferably, the amount of the topcoat in the topcoat layer in step (S.6) is 10-15 g / m 2 .

[0049] According to another aspect of the present invention, the applicant has discovered a stone-plastic floor with a 3D wood texture.

[0050] According to the second aspect, in order to achieve the above-mentioned object of the invention, the present invention is implemented through the following technical solutions:

[0051] A stone-plastic floor with a 3D wood texture prepared by the method described above.

[0052] Therefore, the present invention has the following beneficial effects:

[0053] During the development of the production process for 3D wood-textured SPC flooring, after repeated experiments, the applicant discovered that, compared to SPC substrates, the three-dimensional wood-grain layer in 3D wood-textured SPC flooring is extremely prone to warping and deformation. This is because the three-dimensional wood-grain layer in 3D wood-textured SPC flooring has a multi-layered structure, resulting in an excessively thick layer of paint applied to the SPC substrate surface to create the three-dimensional wood-grain layer. Furthermore, due to the complex production process, certain internal stresses persist within the SPC flooring even after multiple rounds of roller pressing, which cannot be completely eliminated. Furthermore, the 3D wood-textured SPC flooring produced using digital printing is ultra-light and thin, with a thickness of only 2-3 mm and a weight of only 2-3 kg per square meter, less than 10% of that of ordinary flooring materials. The 3D wood-textured SPC flooring also features a solid SPC base layer with a high-density, high-fiber mesh structure composed of stone powder, resulting in exceptional hardness. However, the three-dimensional wood-grain layer, located above the SPC substrate layer, has different shrinkage rates than the SPC substrate layer. When the liquid paint solidifies to form a three-dimensional wood grain layer, its volume will shrink. As the paint is applied layer by layer on the SPC substrate layer, this shrinkage force becomes larger and larger, and continues to accumulate until it gradually reaches a maximum value. The wrinkles and convex deformations of the three-dimensional wood grain layer become more and more obvious. Once this maximum shrinkage force is greater than the bonding force between the SPC substrate and the three-dimensional wood grain layer, it will cause relative slippage between the three-dimensional wood grain layer and the SPC substrate layer, causing the adhesion between the SPC substrate layer and the three-dimensional wood grain layer to decrease, further causing the SPC substrate layer to peel off from the three-dimensional wood grain layer above it. This is consistent with the fact that at the warping deformation site, the peeling of the SPC substrate layer and the three-dimensional wood grain layer above the SPC substrate layer is more obvious. After further exploration, the applicant found that there was obvious oily precipitation on the surface of the white PVC film covering the SPC substrate at the peeling site. The precipitated oily substances continue to accumulate, causing the surface adhesion of the white PVC film to decrease, further reducing the bonding strength between the SPC substrate and the three-dimensional wood grain layer. As a result, when the three-dimensional wood grain layer is subsequently printed directly on the SPC substrate, it is easy to have color overlap and inaccurate patterns, further affecting the simulation effect of the stone plastic floor with 3D wood texture, resulting in poor decorative effect.

[0054] The applicants have creatively discovered that simply by adding a surface treatment step to the base layer above the SPC substrate, the base layer's surface roughness is increased, significantly boosting its surface energy. This results in enhanced adhesion between the SPC substrate and the overlying three-dimensional wood-grain layer, a more stable bond, and superior peel resistance. Furthermore, the wettability of the base layer surface is effectively improved, facilitating adhesion to the paint used to print the three-dimensional wood-grain layer and reducing warping of the three-dimensional wood-grain layer. This further enhances the decorative effect of the three-dimensional wood-grain layer and improves the product quality of the 3D wood-textured SPC flooring. DETAILED DESCRIPTION

[0055] The present invention will be further described below with reference to specific embodiments. Those skilled in the art will be able to implement the present invention based on these descriptions. Furthermore, the embodiments of the present invention described below generally represent only a portion of the present invention, rather than all of the embodiments. Therefore, all other embodiments derived by those skilled in the art based on the embodiments of the present invention without inventive effort should fall within the scope of protection of the present invention.

[0056] According to one aspect of the present invention, the applicant has discovered a method for manufacturing a stone-plastic floor with a 3D wood texture by treating the surface of an SPC substrate layer.

[0057] According to the first aspect, in order to achieve the above-mentioned object of the invention, the present invention is implemented through the following technical solutions:

[0058] A method for manufacturing a stone-plastic floor with a 3D wood texture, comprising at least the following steps:

[0059] (S.1) a step of extruding to obtain a stone plastic floor substrate;

[0060] (S.2) The step of covering the surface of the stone plastic floor substrate with a base color layer;

[0061] (S.3) a step of imparting irregularly distributed holes to the surface of the base color layer;

[0062] (S.4) a step of exciting the surface of the base color layer obtained in the previous step with a high energy beam;

[0063] (S.5) coating at least a portion of the surface of the base color layer obtained in the previous step with a primer, and curing the primer to obtain a primer layer;

[0064] (S.6) The step of forming a color paint layer, a pattern layer, a three-dimensional wood grain layer, and a top paint layer in sequence from bottom to top on at least a portion of the surface of the primer layer.

[0065] During the development of the production process for 3D wood-textured SPC flooring, after repeated experiments, the applicant discovered that, compared to SPC substrates, the three-dimensional wood-grain layer in 3D wood-textured SPC flooring is extremely prone to warping and deformation. This is because the three-dimensional wood-grain layer in 3D wood-textured SPC flooring has a multi-layered structure, resulting in an excessively thick layer of paint applied to the SPC substrate surface to create the three-dimensional wood-grain layer. Furthermore, due to the complex production process, certain internal stresses persist within the SPC flooring even after multiple rounds of roller pressing, which cannot be completely eliminated. Furthermore, the 3D wood-textured SPC flooring produced using digital printing is ultra-light and thin, with a thickness of only 2-3 mm and a weight of only 2-3 kg per square meter, less than 10% of that of ordinary flooring materials. The 3D wood-textured SPC flooring also features a solid SPC base layer with a high-density, high-fiber mesh structure composed of stone powder, resulting in exceptional hardness. However, the three-dimensional wood-grain layer, located above the SPC substrate layer, has different shrinkage rates than the SPC substrate layer. When the liquid paint solidifies to form a three-dimensional wood-grain layer, its volume will shrink. As the paint is applied layer by layer to the SPC substrate layer, this shrinkage force becomes stronger and stronger, and continues to accumulate upward, reaching a maximum value at the top of the three-dimensional wood-grain layer. The three-dimensional wood-grain layer becomes more and more wrinkled and convexly deformed. Once this maximum shrinkage force is greater than the bonding force between the SPC substrate and the three-dimensional wood-grain layer, it will cause relative slippage between the three-dimensional wood-grain layer and the SPC substrate layer, causing the adhesion between the SPC substrate layer and the three-dimensional wood-grain layer to decrease, further causing the SPC substrate layer to peel off from the three-dimensional wood-grain layer above it. This is consistent with the fact that at the warping deformation site, the peeling of the SPC substrate layer and the three-dimensional wood-grain layer above the SPC substrate layer is more obvious. After further exploration, the applicant found that there was obvious oily precipitation on the surface of the white PVC film covering the SPC substrate at the peeling site.

[0066] After research, I learned that flooring manufacturers typically adhere or coat a basecoat film on the surface of the SPC substrate to create a basecoat layer that masks the SPC substrate's inherent color. Over time, small molecule processing aids, plasticizers, lubricants, and other substances contained in the basecoat film gradually migrate to the surface of the basecoat layer, forming a noticeable oily substance. This oily substance accumulates on the basecoat layer, making it prone to color overlap and pattern inaccuracies when subsequently printing a three-dimensional wood grain layer directly on the substrate. This further compromises the simulated 3D wood texture of the SPC flooring, resulting in a poor decorative effect.

[0067] Therefore, the applicant innovatively treats the surface of the base layer above the SPC substrate to remove oily substances precipitated from the base layer, effectively preventing the continued accumulation of the precipitated oil, thereby preventing color overlap and inaccurate patterns when the three-dimensional wood grain layer is subsequently printed directly on the substrate. Furthermore, by providing the surface of the base layer above the SPC substrate with irregularly distributed holes, the surface roughness of the base layer is improved. This also helps the paint of the three-dimensional wood grain layer above the base layer to enter and penetrate downward through the holes, enhancing the adhesion between the SPC substrate layer and the three-dimensional wood grain layer above it, making the bond more stable and effectively enhancing the deformation resistance of the 3D wood-textured SPC flooring, thereby preventing warping and wrinkling. Furthermore, the formation of multiple irregularly distributed holes on the surface of the base layer makes the base layer highly compressive, lightweight, non-absorbent, airtight, wear-resistant, and non-degradable, thereby improving the thermal insulation performance of the 3D wood-textured SPC flooring. It can also play a role in wave blocking, achieving the effect of sound reduction, sound absorption and noise reduction, and improving the practicality of the 3D wood texture stone plastic floor.

[0068] In addition, the applicant also applies high-energy beam stimulation to the surface of the base layer, inducing chemical bond breakage and degradation of the base layer's surface molecules, thereby increasing its surface roughness. During this high-energy beam stimulation process, a large amount of strong oxidants such as ozone are also produced, which oxidize the molecules on the base layer's surface, generating highly polar groups such as carbonyls and peroxides, forming a polar surface layer. This increases its surface energy and facilitates adhesion to the paint used to print the three-dimensional wood grain layer. Simultaneously, the process removes oil, moisture, and dirt from the base layer's surface. Using high-energy beams to erode the base layer's surface significantly improves its surface wettability and adhesion. This further effectively reduces the warping deformation rate of the three-dimensional wood grain layer, enhances its decorative effect, and ensures the product quality of the 3D wood-textured stone-plastic flooring.

[0069] A primer is applied to at least a portion of the surface of the treated base color layer, and then cured to form a primer layer. A color paint, ink for forming a color pattern layer, paint for forming a three-dimensional wood grain layer, and a topcoat for protecting the three-dimensional wood grain layer and providing other functional properties (such as antibacterial, antistatic, and wear-resistant properties) are sequentially applied to at least a portion of the surface of the primer layer from bottom to top, thereby forming a color paint layer, a pattern layer, a three-dimensional wood grain layer, and a topcoat layer.

[0070] In a preferred embodiment of the present invention, the process of obtaining the base color layer in step (S.2) includes:

[0071] The step of covering the surface of the stone plastic floor substrate with a base color film.

[0072] In a preferred embodiment of the present invention, a stone plastic flooring substrate (i.e., an SPC substrate) and a base film (i.e., a PVC film) can be laminated together through online lamination. The raw materials and additives that make up the SPC substrate are added to a main extruder, which melts the raw materials and additives and squeezes them into the main flow channel of a mold. The SPC substrate layer is then extruded from the mold to form the SPC substrate layer. The PVC film that forms the base layer is unwound and rolled online with the SPC substrate layer to form the SPC substrate layer, resulting in an SPC substrate layer covered with PVC film.

[0073] In another preferred embodiment of the present invention, the SPC substrate and the base film (i.e., PVC film) can also be co-extruded. The raw materials and additives constituting the SPC substrate are added to a main extruder, where they are melted and extruded into the main flow channel of a mold. The film is then extruded from the mold to form the SPC substrate layer. The PVC raw materials and additives constituting the PVC film are added to an auxiliary extruder, where they are melted and extruded into the auxiliary flow channel of the mold. The film then diffuses within the co-extrusion casting space of the mold, coating the SPC substrate layer. The film is then cured and shaped through heat exchange with the cooling channel plates within the mold. Finally, the film is extruded from the mold to form the SPC substrate layer, with the surface covered by the PVC film.

[0074] In another preferred embodiment of the present invention, the SPC substrate is obtained by extrusion molding. After the SPC substrate is extruded, one or more layers of white paint are coated on its surface, thereby forming a base color layer on the surface of the SPC substrate.

[0075] Coating the SPC substrate with one or more layers of PVC film or white paint conceals the SPC substrate's base color, effectively preventing color overlap, inaccurate color rendering, and significant color variation during subsequent color pattern printing on the SPC substrate. Laminating the SPC substrate and PVC film together through in-line lamination effectively shortens the process, streamlines the process, improves controllability, and enhances production efficiency. In contrast, the surface of the PVC film laminated with the SPC substrate via coextrusion is very smooth, resulting in poor results when directly printed, and even causing issues such as ghosting. Furthermore, coating the SPC substrate with white paint has a strong odor and is difficult to evaporate, posing a risk to the human body. This process is costly and can easily lead to problems such as sagging, yellowing, wrinkling, and cracking on the SPC substrate surface. Furthermore, the evaporation of water, solvents, and other substances in the white paint can expose the substrate's base color, further leading to color instability and significant color variation during subsequent printing. Furthermore, the long drying time and the large space required for white paint reduce the efficiency of the SPC flooring manufacturing process.

[0076] In a preferred embodiment of the present invention, the base color layer comprises at least one or more of a polyvinyl chloride resin, a colorant, a plasticizer, a heat stabilizer, and a lubricant.

[0077] The primary component of the base layer (also known as the base film) is polyvinyl chloride (PVC). Due to its low linear expansion coefficient, PVC offers excellent fire resistance and flame retardancy. PVC is also chemically stable, offering outstanding resistance to chemical organic solvents and corrosion. Based on the final color requirements of the SPC flooring product, appropriate colorants can be added to the base film to mask the inherent color of the SPC substrate. This further prevents overlapping colors, inaccurate color rendering, and significant color shift in the printed pattern. Because the base film's viscosity and degradation temperatures are close, it is susceptible to various forms of degradation during processing, resulting in loss of performance. Therefore, heat stabilizers and lubricants are added to the base film formulation to improve its thermal stability. This also reduces friction between the PVC molecular chains in the base film, preventing the melted PVC from sticking to the equipment and facilitating film removal during extrusion molding. Adding plasticizers to the base film formulation softens the PVC and effectively reduces the processing temperature. PVC plasticizers are often small-molecule phthalates. In PVC systems, these plasticizers do not participate in the polymerization of the PVC molecular chains, but instead bind to them through hydrogen bonds or van der Waals forces. Consequently, they often evaporate, migrate, and leach out during use. This migration of plasticizers can easily cause the base film to become hard, brittle, or even break. Plasticizers precipitated from the base film surface can also pollute the environment.

[0078] In another preferred embodiment of the present invention, the base color layer may further include one or more combinations of light stabilizers, antioxidants, impact modifiers, fillers, processing aids, antistatic agents, flame retardants, and biocides.

[0079] Light stabilizers prevent ultraviolet radiation from degrading the PVC in the base film. Antioxidants prevent oxygen from degrading PVC. Impact modifiers increase the toughness of PVC. Fillers are used to reduce production costs. Processing aids improve processing performance and plasticity. Antistatic agents reduce static electricity accumulation on the surface of the base film, eliminating the potential hazards of static electricity accumulation. Flame retardants enhance the flame retardancy of the base film. Biocides inhibit bacteria and mildew, preventing the base film from being degraded by microorganisms and enhancing its antimicrobial properties.

[0080] In a preferred embodiment of the present invention, the base color layer is white and has a thickness of 0.05-0.15 mm.

[0081] In a preferred embodiment of the present invention, the softening temperature of the base color layer is 70-85°C.

[0082] When the surface temperature of the base layer is between 70 and 85 degrees Celsius, the base layer begins to soften and become sticky. Since the PVC in the base layer has poor thermal stability, continued heating to above 120 degrees Celsius will cause it to decompose and slowly release hydrogen chloride gas, causing the base layer to change color.

[0083] In a preferred embodiment of the present invention, the process of imparting irregularly distributed holes to the surface of the base color layer in step (S.3) comprises:

[0084] The step of making the surface of the base color layer contact with the grinding tool and thus be polished.

[0085] The surface of the base layer is sanded using a flexible grinding tool and fine abrasive particles or other polishing media to remove oily substances, bubbles, wood burrs, and dust particles precipitated from the base layer. Simultaneously, the sanding treatment creates a number of irregularly distributed holes on the base layer, increasing its surface roughness and further enhancing its adhesion. Furthermore, these holes allow the paint or coating used to form the three-dimensional wood grain layer above the base layer to enter and penetrate downward, strengthening the adhesion between the base layer and the SPC substrate layer, as well as the three-dimensional wood grain layer above it, and ensuring a more stable bond. This further effectively enhances the deformation resistance of the SPC flooring with a 3D wood texture, preventing warping and wrinkling. Furthermore, this arrangement effectively reduces the apparent saturation of the base layer surface, resulting in a lower surface gloss. This increases diffuse reflection and reduces specular reflection from the base layer surface, further imparting a matte finish to the SPC flooring with a 3D wood texture.

[0086] In a further preferred embodiment of the present invention, the process of imparting irregularly distributed holes to the surface of the base layer in step (S.3) includes the step of contacting the surface of the base layer with a grinding tool to thereby grind it. The grinding method includes hand grinding and / or machine grinding. Machine grinding is time-efficient, can sand large areas, helps improve production efficiency, and achieves uniform sanding.

[0087] In a further preferred embodiment of the present invention, the process of imparting irregularly distributed holes to the surface of the base layer in step (S.3) includes the step of contacting the surface of the base layer with a grinding tool to thereby grind it. The grinding method includes one or more of dry grinding, water grinding, oil grinding, wax grinding, polishing with polishing paste, electrolytic polishing, ultrasonic polishing, magnetic abrasive polishing, and fluid polishing.

[0088] In a further preferred embodiment of the present invention, the process of imparting irregularly distributed holes to the surface of the base layer in step (S.3) includes the step of contacting the base layer surface with a grinding tool to thereby grind it. Dry grinding can include a combination of one or more of coarse grinding, flat grinding, and fine grinding. Coarse grinding can remove oily substances, bubbles caused by improper operation, wood burrs, and dust particles from the base layer surface. Flat grinding often uses emery cloth or sandpaper wrapped with a small wooden block or hard eraser to smooth the base layer surface, making it smoother. Fine grinding has higher requirements for the coarseness of the abrasive particles; finer abrasive particles are often used to increase the smoothness of the base layer surface, resulting in a better polishing effect.

[0089] In a further preferred embodiment of the present invention, the process of imparting irregularly distributed holes to the surface of the base layer in step (S.3) includes the step of causing the surface of the base layer to contact a grinding tool and thereby be polished. The polishing direction is along the direction of the wood grain. Avoid horizontal polishing or random polishing that leaves messy sand marks on the surface of the base layer. When using a different type of abrasive, the polishing direction should be altered by 30° to 45° from the previous polishing direction to avoid carrying coarse sand particles into the next finer grinding operation. During polishing, care should also be taken to polish gently to prevent the protruding areas such as lines and corners on the surface of the base layer from being damaged, collapsed, or deformed by sand, thereby affecting the smoothness and beauty of the lines, corners, and other external shapes.

[0090] In a preferred embodiment of the present invention, the surface roughness Ra value of the base color layer after contacting the grinding tool is 0.3-1.6 μm.

[0091] In a preferred embodiment of the present invention, the grinding tool is any one of a belt sander, a belt grinder, and a belt polisher.

[0092] In a preferred embodiment of the present invention, the abrasive tool comprises a combination of one or more of abrasive belts, sandpaper, and gauze.

[0093] In a further preferred embodiment of the present invention, the abrasive tool comprises an abrasive belt having a mesh size of 120 to 320. When the abrasive belt has a mesh size higher than 320 and the surface roughness Ra value of the base layer after contact with the abrasive tool is lower than 0.3 μm, the finer the abrasive belt particles, the smoother and flatter the surface of the base layer after being sanded by the abrasive belt, which can easily reduce the adhesion of the base layer surface. When the abrasive belt has a mesh size lower than 120 and the surface roughness Ra value of the base layer after contact with the abrasive tool is higher than 1.6 μm, the abrasive belt particles are too coarse, resulting in an excessively rough surface of the base layer after sanding. This reduces the effective contact area between the base layer and the SPC substrate layer and the three-dimensional wood grain layer, resulting in excessive pressure, excessive frictional resistance, rapid wear, and reduced wear resistance. Furthermore, excessively rough surface of the base layer after sanding by the abrasive belt can result in numerous pits, requiring additional primer to fill the pits during subsequent printing to prevent image clarity from being affected.

[0094] In a preferred embodiment of the present invention, the process of subjecting the surface of the base color layer to high energy beam stimulation in step (S.4) includes:

[0095] The step of subjecting the surface of the base color layer to high-frequency high-voltage corona discharge.

[0096] The primary component of the base film is PVC, a non-polar polymer with low surface tension. Most known paints and adhesives used to create the three-dimensional wood grain layer have difficulty adhering firmly to the base film's surface. By subjecting the base layer surface to corona treatment, the chemical bonds within the PVC molecules are broken, leading to degradation and increased surface roughness. During the corona discharge process, a large amount of ozone is also produced. Ozone is a strong oxidant that oxidizes PVC molecules, producing highly polar groups such as carbonyls and peroxides, thereby increasing their surface energy. This improves the adhesion of the base layer surface, enhances its affinity with paints and coatings, and facilitates bonding with the paint used to print the three-dimensional wood grain layer. It also removes oil, moisture, and dirt from the base layer surface, helping to improve the visual effect. Furthermore, high-frequency and high-voltage (high-frequency AC voltage of up to 5,000 to 15,000 V / m 2 ) Corona discharge is generated on the surface of the treated base layer, generating low-temperature plasma. This causes free radical reactions on the surface of the base layer, which cross-links the polymers and increases their wettability to polar solvents, making paints and other materials more easily penetrated. This further effectively reduces the warping deformation rate of the three-dimensional wood grain layer, improves the decorative effect of the three-dimensional wood grain layer, and ensures the product quality of the 3D wood texture stone plastic floor.

[0097] In a preferred embodiment of the present invention, the current of the high-frequency and high-voltage corona discharge is 4-8A.

[0098] In a preferred embodiment of the present invention, the surface tension of the base color layer after being stimulated by the high-energy beam is 36-40 mN / m.

[0099] When the surface tension of the base layer after high-energy beam stimulation is less than 36mN / m and the current of high-frequency, high-voltage corona discharge is less than 4A, the wettability of the base layer surface does not improve significantly and its surface viscosity is very poor, making it difficult to apply paint for printing a three-dimensional wood grain layer, and the three-dimensional wood grain layer is difficult to display. When the surface tension of the base layer after high-energy beam stimulation is greater than 40mN / m and the current of high-frequency, high-voltage corona discharge is greater than 8A, the base layer surface is prone to film adhesion and paint back-sticking. More seriously, corona breakdown may occur, creating micropores and compromising the sealing and barrier properties of the base layer.

[0100] In a preferred embodiment of the present invention, the surface of the base color layer is subjected to high-frequency and high-voltage corona discharge at a rate of 15-30 m / min.

[0101] The surface of the base layer is subjected to high-frequency and high-voltage corona discharge at a rate that is consistent with the transmission speed of the SPC substrate on the production process line, so that the output power during corona treatment remains stable, further ensuring the stability of the output voltage, thereby achieving better corona treatment effects.

[0102] In a preferred embodiment of the present invention, the distance between the surface of the base color layer and the discharge electrode applying high frequency and high voltage electricity is 2 to 5 cm.

[0103] When the distance between the base layer surface and the discharge electrode applying high-frequency high-voltage electricity is less than 2 cm, the energy released by the discharge electrode is very likely to cause corona breakdown, which will damage the sealing and barrier properties of the base layer. When the distance between the base layer surface and the discharge electrode applying high-frequency high-voltage electricity is greater than 5 cm, the energy released by the discharge electrode is dispersed into a larger space, the intensity of the corona treatment is reduced, and the treatment effect becomes worse.

[0104] In another preferred embodiment of the present invention, the process of subjecting the surface of the base color layer to high energy beam stimulation in step (S.4) includes:

[0105] The step of exciting the surface of the base color layer with a laser beam.

[0106] The surface of the base color layer is processed by a laser beam so that most of the laser is absorbed by the surface of the base color layer and a smaller portion of the laser is reflected from the surface of the base color layer, thereby changing the composition and microstructure of the surface of the base color layer and increasing the roughness of the surface of the base color layer.

[0107] In a preferred embodiment of the present invention, the primer in step (S.5) comprises at least a photo-crosslinking resin and a photoinitiator.

[0108] In a preferred embodiment of the present invention, the photo-crosslinking resin includes any one or more combinations of unsaturated polyester, epoxy resin, acrylic resin, acrylic modified polyurethane resin, acrylic modified silicone resin, acrylic modified epoxy resin, water-based epoxy acrylate, water-based polyurethane acrylate, and water-based polyester acrylate.

[0109] In a preferred embodiment of the present invention, the photoinitiator includes any one of a free radical polymerization initiator, a cationic polymerization initiator, an energy transfer initiator, and an ion reaction initiator.

[0110] In a preferred embodiment of the present invention, the amount of the primer applied to the surface of the base color layer in step (S.5) is 10-15 g / m 2 .

[0111] In a preferred embodiment of the present invention, the color paint layer in step (S.6) is white, and the amount of the color paint in the color paint layer is 15-25 g / m 2 .

[0112] In a preferred embodiment of the present invention, the process of forming the pattern layer in step (S.6) includes:

[0113] The step of coating at least a portion of the surface of the color paint layer with ink for forming a wood grain pattern and curing the ink to obtain a pattern layer.

[0114] In a preferred embodiment of the present invention, the amount of ink used in the pattern layer in step (S.6) is 6-10 g / m 2 .

[0115] In a preferred embodiment of the present invention, the process of forming the three-dimensional wood grain layer in step (S.6) includes:

[0116] The step of covering at least a portion of the surface of the pattern layer with a three-dimensional wood grain layer having a three-dimensional structure.

[0117] In a preferred embodiment of the present invention, the process of forming the topcoat layer in step (S.6) includes:

[0118] The step of coating at least a portion of the surface of the three-dimensional wood grain layer with a topcoat and curing the topcoat to obtain a topcoat layer.

[0119] In a preferred embodiment of the present invention, the amount of the topcoat in the topcoat layer in step (S.6) is 10-15 g / m 2 .

[0120] According to another aspect of the present invention, the applicant has discovered a stone-plastic floor with a 3D wood texture.

[0121] According to the second aspect, in order to achieve the above-mentioned object of the invention, the present invention is implemented through the following technical solutions:

[0122] A stone-plastic floor with a 3D wood texture prepared by the method described above.

[0123] Example 1

[0124] This embodiment provides a method for manufacturing a stone-plastic floor with a 3D wood texture, comprising the following steps:

[0125] (S.1) The raw materials and additives constituting the SPC substrate are added to a main extruder, the raw materials and additives constituting the substrate are melted by the main extruder, extruded into the main channel of the mold, and then extruded from the mold to form an SPC substrate layer;

[0126] (S.2) unwinding a 0.07 mm thick PVC white film (having a softening temperature of 80°C) constituting the base color layer and rolling the film together with the SPC substrate layer obtained in step (S.1) to obtain an SPC substrate layer having a surface covered with the PVC white film;

[0127] (S.3) sanding the surface of the PVC white film using a sanding belt machine (grit number 240) so that the surface roughness Ra value of the sanded PVC white film is 0.6 μm;

[0128] (S.4) applying a high-frequency high-voltage electric current of 6 A, a discharge rate of 30 m / min, and a distance of 4 cm between the surface of the PVC white film and the discharge electrode applying the high-frequency high-voltage electric current to the surface of the PVC white film after sanding in step (S.3) using a corona treatment machine, so that the surface tension of the PVC white film after the corona treatment is 38 mN / m;

[0129] (S.5) Apply primer to the surface of the corona-treated PVC white film obtained in step (S.4), with the amount of primer being 12 g / m 2 Then, irradiating the primer with 160w / cm3 ultraviolet light generated by a medium-pressure Hg lamp to cure the primer to obtain a primer layer;

[0130] (S.6) The surface of the primer layer obtained in step (S.5) is coated with a color paint, ink for forming a pattern layer, paint or coating for forming a three-dimensional wood grain layer, and a topcoat for protecting the three-dimensional wood grain layer in order from bottom to top, and then irradiated with 160w / cm2 ultraviolet light generated by a medium-pressure Hg lamp to form a color paint layer, a pattern layer, a three-dimensional wood grain layer, and a topcoat layer in order. The amount of color paint used is 17g / m 2The amount of ink used to form the pattern layer is 7g / m 2 The amount of paint used to form the three-dimensional wood grain layer is 205g / m 2 , the amount of topcoat is 12g / m 2 .

[0131] This embodiment also provides a stone-plastic floor with a 3D wood texture prepared by the method described above.

[0132] Example 2

[0133] The difference between this embodiment and embodiment 1 is that:

[0134] This example provides a method for manufacturing a 3D wood-textured stone-plastic floor. In step (S.3), the sanding belt has a mesh size of 120, resulting in a surface roughness Ra of 1.6 μm after sanding the PVC white film. All other conditions are the same as in Example 1.

[0135] Example 3

[0136] The difference between this embodiment and embodiment 1 is that:

[0137] This example provides a method for manufacturing a 3D wood-textured stone-plastic floor. In step (S.3), the sanding belt has a mesh size of 180, resulting in a surface roughness Ra of 0.8 μm for the sanded PVC white film. All other conditions are the same as in Example 1.

[0138] Example 4

[0139] The difference between this embodiment and embodiment 1 is that:

[0140] This example provides a method for manufacturing a 3D wood-textured stone-plastic floor. In step (S.3), the sanding belt has a mesh size of 320, resulting in a surface roughness Ra of 0.3 μm for the sanded PVC white film. All other conditions are the same as in Example 1.

[0141] Example 5

[0142] The difference between this embodiment and embodiment 1 is that:

[0143] This example provides a method for manufacturing a 3D wood-textured stone-plastic floor. In step (S.4), a corona treatment machine is used to apply a high-frequency, high-voltage current of 4A to the surface of the sanded PVC white film in step (S.3), thereby generating corona discharge. This method results in a surface tension of 36 mN / m for the treated PVC white film. All other steps are the same as those in Example 1.

[0144] Example 6

[0145] The difference between this embodiment and embodiment 1 is that:

[0146] This example provides a method for manufacturing a 3D wood-textured stone-plastic floor. In step (S.4), a corona treatment machine is used to apply a high-frequency, high-voltage current of 8A to the surface of the sanded white PVC film in step (S.3), thereby generating corona discharge. This results in a surface tension of 40 mN / m for the treated PVC film. All other steps are the same as those in Example 1.

[0147] Example 7

[0148] The difference between this embodiment and embodiment 1 is that:

[0149] This example provides a method for manufacturing a 3D wood-textured stone-plastic floor. In step (S.4), a corona treatment apparatus is used to apply high-frequency, high-voltage electricity at a discharge rate of 15 m / min to the surface of the sanded PVC white film in step (S.3). All other steps are the same as in Example 1.

[0150] Example 8

[0151] The difference between this embodiment and embodiment 1 is that:

[0152] This example provides a method for manufacturing a 3D wood-textured stone-plastic floor. In step (S.4), a corona treatment apparatus is used to apply high-frequency, high-voltage electricity at a discharge rate of 22 m / min to the surface of the sanded PVC white film in step (S.3). All other steps are the same as in Example 1.

[0153] Example 9

[0154] The difference between this embodiment and embodiment 1 is that:

[0155] This example provides a method for manufacturing a 3D wood-textured stone-plastic floor. In step (S.4), a corona treatment apparatus is used to apply high-frequency, high-voltage electricity to the surface of the sanded PVC white film in step (S.3) to generate corona discharge, ensuring a distance of 2 cm between the surface of the PVC white film and the discharge electrode applying the high-frequency, high-voltage electricity. All other steps are the same as in Example 1.

[0156] Example 10

[0157] The difference between this embodiment and embodiment 1 is that:

[0158] This example provides a method for manufacturing a 3D wood-textured stone-plastic floor. In step (S.4), a corona treatment apparatus is used to apply high-frequency, high-voltage electricity to the surface of the sanded PVC white film in step (S.3) to generate corona discharge, ensuring a distance of 5 cm between the surface of the PVC white film and the discharge electrode applying the high-frequency, high-voltage electricity. All other steps are the same as in Example 1.

[0159] Example 11

[0160] This embodiment provides a method for manufacturing a stone-plastic floor with a 3D wood texture, comprising the following steps:

[0161] (S.1) The raw materials and additives constituting the SPC substrate are added to a main extruder, the raw materials and additives constituting the substrate are melted by the main extruder, extruded into the main channel of the mold, and then extruded from the mold to form an SPC substrate layer;

[0162] (S.2) unwinding a 0.05 mm thick PVC white film (having a softening temperature of 70°C) constituting the base color layer and rolling the film together with the SPC substrate layer obtained in step (S.1) to obtain an SPC substrate layer having a surface covered with the PVC white film;

[0163] (S.3) sanding the surface of the PVC white film using a sanding belt machine (grit number 240) so that the surface roughness Ra value of the sanded PVC white film is 0.6 μm;

[0164] (S.4) applying a high-frequency high-voltage electric current of 6 A, a discharge rate of 30 m / min, and a distance of 4 cm between the surface of the PVC white film and the discharge electrode applying the high-frequency high-voltage electric current to the surface of the PVC white film after sanding in step (S.3) using a corona treatment machine, so that the surface tension of the PVC white film after the corona treatment is 38 mN / m;

[0165] (S.5) Apply primer to the surface of the corona-treated PVC white film obtained in step (S.4), with the amount of primer being 10 g / m 2 Then, irradiating the primer with 160w / cm3 ultraviolet light generated by a medium-pressure Hg lamp to cure the primer to obtain a primer layer;

[0166] (S.6) The surface of the primer layer obtained in step (S.5) is coated with a color paint, ink for forming a pattern layer, paint or coating for forming a three-dimensional wood grain layer, and a topcoat for protecting the three-dimensional wood grain layer in order from bottom to top, thereby forming a color paint layer, a pattern layer, a three-dimensional wood grain layer, and a topcoat layer in order. The amount of color paint used is 15g / m 2 Then, it is irradiated with 160w / cm3 of ultraviolet light generated by a medium pressure Hg lamp. The amount of ink used to form the pattern layer is 6g / m2 The amount of paint used to form the three-dimensional wood grain layer is 100g / m 2 , the amount of topcoat is 10g / m 2 .

[0167] This embodiment also provides a stone-plastic floor with a 3D wood texture prepared by the method described above.

[0168] Example 12

[0169] This embodiment provides a method for manufacturing a stone-plastic floor with a 3D wood texture, comprising the following steps:

[0170] (S.1) The raw materials and additives constituting the SPC substrate are added to a main extruder, the raw materials and additives constituting the substrate are melted by the main extruder, extruded into the main channel of the mold, and then extruded from the mold to form an SPC substrate layer;

[0171] (S.2) unwinding a 0.15 mm thick PVC white film (having a softening temperature of 85°C) constituting the base color layer and rolling the film together with the SPC substrate layer obtained in step (S.1) to obtain an SPC substrate layer having a surface covered with the PVC white film;

[0172] (S.3) sanding the surface of the PVC white film using a sanding belt machine (grit number 240) so that the surface roughness Ra value of the sanded PVC white film is 0.6 μm;

[0173] (S.4) applying a high-frequency high-voltage electric current of 6 A, a discharge rate of 30 m / min, and a distance of 4 cm between the surface of the PVC white film and the discharge electrode applying the high-frequency high-voltage electric current to the surface of the PVC white film after sanding in step (S.3) using a corona treatment machine, so that the surface tension of the PVC white film after the corona treatment is 38 mN / m;

[0174] (S.5) Apply primer to the surface of the corona-treated PVC white film obtained in step (S.4), with the amount of primer being 15 g / m 2 Then, irradiating the primer with 160w / cm3 ultraviolet light generated by a medium-pressure Hg lamp to cure the primer to obtain a primer layer;

[0175] (S.6) The surface of the primer layer obtained in step (S.5) is coated with a color paint, ink for forming a pattern layer, paint or coating for forming a three-dimensional wood grain layer, and a topcoat for protecting the three-dimensional wood grain layer in order from bottom to top, thereby forming a color paint layer, a pattern layer, a three-dimensional wood grain layer, and a topcoat layer in order. The amount of the color paint is 25g / m 2Then, it is irradiated with 160w / cm3 ultraviolet light generated by a medium pressure Hg lamp. The amount of ink used to form the pattern layer is 10g / m 2 The amount of paint or coating used to form the three-dimensional wood grain layer is 220g / m 2 , the amount of topcoat is 15g / m 2 .

[0176] This embodiment also provides a stone-plastic floor with a 3D wood texture prepared by the method described above.

[0177] Example 13

[0178] The difference between this embodiment and embodiment 1 is that:

[0179] This embodiment provides a method for manufacturing a 3D wood-textured stone-plastic floor. In step (S.2), the PVC raw materials and additives that constitute the base layer are added to an auxiliary extruder. The PVC raw materials and additives that constitute the base layer are melted by the auxiliary extruder and extruded into the auxiliary flow channel of the mold. The PVC raw materials and additives then diffuse within the co-extrusion casting space of the mold, coating the SPC substrate layer. The SPC substrate layer is then cured and shaped through heat exchange with the cooling flow channel plates within the mold. Finally, the SPC substrate layer is extruded from the mold, resulting in an SPC substrate layer with a base film covering its surface. All other steps are the same as in Example 1.

[0180] Example 14

[0181] The difference between this embodiment and embodiment 1 is that:

[0182] This example provides a method for manufacturing a 3D wood-textured stone-plastic floor. In step (S.2), after the SPC substrate is extruded, its surface is coated with one or more layers of white paint, thereby producing an SPC substrate layer covered with white paint. All other steps are the same as in Example 1.

[0183] Example 15

[0184] The difference between this embodiment and embodiment 1 is that:

[0185] This example provides a method for manufacturing a 3D wood-textured stone-plastic floor. In step (S.3), the surface of the PVC white film is wiped with an organic solvent such as acetone using a flexible cleaning tool such as a soft cloth or soft-bristled brush, resulting in a surface roughness Ra of 0.6 μm after wiping. All other steps are the same as in Example 1.

[0186] Example 16

[0187] The difference between this embodiment and embodiment 1 is that:

[0188] This example provides a method for manufacturing a 3D wood-textured stone-plastic floor. In step (S.4), a carbon dioxide laser with a laser power of 400 W is used to heat-treat the surface of the sanded PVC white film in step (S.3). All other steps are the same as in Example 1.

[0189] Comparative Example 1

[0190] The difference between this embodiment and embodiment 1 is that:

[0191] This example provides a method for manufacturing a 3D wood-textured stone-plastic floor. In step (S.3), the sanding belt has a mesh size of 100, resulting in a surface roughness Ra of 3.2 μm for the sanded PVC white film. All other conditions are the same as in Example 1.

[0192] Comparative Example 2

[0193] The difference between this embodiment and embodiment 1 is that:

[0194] This example provides a method for manufacturing a 3D wood-textured stone-plastic floor. In step (S.3), the sanding belt has a mesh size of 400, resulting in a surface roughness Ra of 0.1 μm for the sanded PVC white film. All other conditions are the same as in Example 1.

[0195] Comparative Example 3

[0196] The difference between this embodiment and embodiment 1 is that:

[0197] This example provides a method for manufacturing a 3D wood-textured stone-plastic floor. In step (S.4), a corona treatment machine is used to apply a high-frequency, high-voltage current of 2A to the surface of the sanded white PVC film in step (S.3), thereby generating corona discharge. This method results in a surface tension of 34 mN / m for the treated PVC film. All other steps are the same as those in Example 1.

[0198] Comparative Example 4

[0199] The difference between this embodiment and embodiment 1 is that:

[0200] This example provides a method for manufacturing a 3D wood-textured stone-plastic floor. In step (S.4), a corona treatment machine is used to apply a high-frequency, high-voltage current of 10A to the surface of the sanded white PVC film in step (S.3), thereby generating corona discharge. This results in a surface tension of 42 mN / m for the treated PVC film. All other steps are the same as those in Example 1.

[0201]

Performance test

[0202]

Warp test

[0203] Fifty pieces of 3D wood-textured SPC flooring panels were mass-produced according to the methods described in Examples 1-16 and Comparative Examples 1-4. The panels were then cut into 240 mm x 240 mm specimens, and their initial warpage and heating warpage were measured. The test procedure was as follows: the 3D wood-textured SPC flooring panels were placed on an aluminum plate with the 3D wood-textured layer facing upwards. The panels were then placed at 23±2°C and 50±5% RH for 24 hours, and their average initial warpage was measured using a caliper. The temperature in a constant-temperature drying oven was adjusted to 80°C, and the panel samples, along with the aluminum plate, were placed in the oven for 6 hours. The panel samples, along with the aluminum plate, were then removed and placed at 23±2°C and 50±5% RH for 24 hours. The average heating warpage of the panel samples was then measured using a caliper. The test results are shown in Table 1 below.

[0204]

[0205]

Immersion peeling test

[0206] 3D wood-textured SPC flooring panels were prepared according to the methods described in Examples 1-16 and Comparative Examples 1-4. The panels were tested for immersion peelability in accordance with GB / T 17657-2013, "Test Methods for Physical and Chemical Properties of Wood-Based Panels and Finished Wood-Based Panels." The immersion peelability test method involved cutting a 75 mm long and 75 mm wide sample from each panel. Each sample was immersed in 100°C boiling water for 4 hours, removed and dried in a 63°C drying oven for 20 hours. The sample was then immersed in 100°C boiling water for 4 hours, removed and dried in a 63°C drying oven for 3 hours. The entire sample was immersed in the boiling water. The sample was carefully observed for peeling or delamination between the paint layers and the SPC substrate layer. The length of the peeled or delaminated portion on each side of the paint layer was measured using a steel ruler. If the peeling or delamination on one side occurred in multiple sections, the lengths were cumulatively added. The test results are shown in Table 2 below.

[0207]

[0208] Analysis of the data in Tables 1 and 2 shows that the surface of the PVC film was sanded using a 240-grit sanding belt, resulting in a surface roughness Ra of 0.6 μm. Corona discharge was then applied to the sanded surface using a corona treatment machine at a current of 6 A, a discharge rate of 30 m / min, and a distance of 4 cm between the film surface and the discharge electrode. This resulted in a surface tension of 38 mN / m after corona treatment. This significantly improved the adhesion of the PVC film surface, significantly improving the minimum length of peeling or delamination on each side of the paint layer of the resulting 3D wood-textured SPC flooring. This demonstrates that the sanded and corona-treated PVC film strengthens the adhesion between the SPC substrate layer and the three-dimensional wood-grain layer above it, making the bond more stable and effectively reducing the warping of the three-dimensional wood-grain layer.

[0209] The above description is only a detailed description of the preferred embodiments and principles of the present invention. For ordinary technicians in this field, based on the ideas provided by the present invention, there may be changes in the specific implementation methods, and these changes should also be considered as the scope of protection of the present invention.

Claims

1. A method for manufacturing stone-plastic composite (SPC) flooring with 3D wood grain texture, characterized in that it comprises at least the following steps:(S.1) Extruding to form an SPC flooring substrate;(S.2) Covering the surface of the SPC flooring substrate with a base color layer, wherein the base color layer comprises a base color film;(S.3) Imparting irregularly distributed pores on the surface of the base color layer, wherein small-molecule processing aids, plasticizers, lubricants and other substances contained in the base color film migrate to the surface of the base color layer to form oily substances, and wherein the surface of the base color layer is treated to remove the oily substances exuding on the surface of the base color layer;(S.4) Subjecting the surface of the base color layer obtained in the previous step to high-energy beam stimulation;(S.5) Coating at least a portion of the surface of the base color layer obtained in the previous step with a primer and curing it to form a primer layer;(S.6) Sequentially forming, from bottom to top, a color paint layer, a pattern layer, a three-dimensional wood grain layer, and a topcoat layer on at least a portion of the surface of the primer layer.

2. The method for manufacturing SPC flooring with 3D wood grain texture according to claim 1, characterized in that the base color layer comprises at least one or a combination of polyvinyl chloride resin, colorant, plasticizer, heat stabilizer, and lubricant.

3. The method for manufacturing SPC flooring with 3D wood grain texture according to claim 1, characterized in that the base color layer is white and has a thickness of 0.05 to 0.15 mm.2024242291   24 Sep 20264. The method for manufacturing SPC flooring with 3D wood grain texture according to claim 1, characterized in that the process of imparting irregularly distributed pores on the surface of the base color layer in step (S.3) comprises:Polishing the surface of the base color layer by contacting it with an abrasive tool.

5. The method for manufacturing SPC flooring with 3D wood grain texture according to claim 4, characterized in that the surface roughness Ra of the base color layer after contact with the abrasive tool is 0.3 to 1.6 pm.

6. The method for manufacturing SPC flooring with 3D wood grain texture according to claim 1, characterized in that the process of subjecting the surface of the base color layer to high-energy beam stimulation in step (S.4) comprises:Subjecting the surface of the base color layer to high-frequency, high-voltage corona discharge.

7. The method for manufacturing SPC flooring with 3D wood grain texture according to claim 1 or 6, characterized in that the surface tension of the base color layer surface after high-energy beam stimulation is 36 to 40 mN / m.

8. The method for manufacturing SPC flooring with 3D wood grain texture according to claim 1 or 6, characterized in that the rate of subjecting the surface of the base color layer to high-frequency, high-voltage corona discharge is 15 to 30 m / min.

9. The method for manufacturing SPC flooring with 3D wood grain texture according to claim 6, characterized in that the distance between the surface of the base color layer and the discharge electrode applying the high-frequency, high-voltage electricity is 2 to 5 cm.2024242291   24 Sep 202610. The method for manufacturing SPC flooring with 3D wood grain texture according to claim 1, characterized in that the primer in step (S.5) comprises at least a photocrosslinkable resin and a photoinitiator.

11. The method for manufacturing SPC flooring with 3D wood grain texture according to claim 10, characterized in that the photocrosslinkable resin comprises one or a combination of unsaturated polyester, epoxy resin, acrylic resin, acrylic-modified polyurethane resin, acrylic-modified silicone resin, acrylic-modified epoxy resin, water-based epoxy acrylate, water-based polyurethane acrylate, or water-based polyester acrylate.

12. The method for manufacturing SPC flooring with 3D wood grain texture according to claim 1 or 10, characterized in that the amount of primer applied to the surface of the base color layer in step (S.5) is 10 to 15 g / m2.

13. The method for manufacturing SPC flooring with 3D wood grain texture according to claim 1, characterized in that the color paint layer in step (S.6) is white, and the amount of color paint used for the color paint layer is 15 to 25 g / m2.

14. The method for manufacturing SPC flooring with 3D wood grain texture according to claim 1, characterized in that the process of forming the pattern layer in step (S.6) comprises:Coating at least a portion of the surface of the color paint layer with ink to form a wood grain pattern and curing it to obtain the pattern layer.

15. The method for manufacturing SPC flooring with 3D wood grain texture according to claim 1 or 14, characterized in that the amount of ink used for the pattern layer in step (S.6) is 6 to 10 g / m2.2024242291   24 Sep 202616. The method for manufacturing SPC flooring with 3D wood grain texture according to claim 1, characterized in that the process of forming the three-dimensional wood grain layer in step (S.6) comprises:Covering at least a portion of the surface of the pattern layer with a three-dimensional wood grain layer having a three-dimensional structure.

17. The method for manufacturing SPC flooring with 3D wood grain texture according to claim 1, characterized in that the process of forming the topcoat layer in step (S.6) comprises:Coating at least a portion of the surface of the three-dimensional wood grain layer with a topcoat and curing it to obtain the topcoat layer.

18. The method for manufacturing SPC flooring with 3D wood grain texture according to claim 1 or 17, characterized in that the amount of topcoat used for the topcoat layer in step (S.6) is 10 to 15 g / m2.

19. An SPC flooring with 3D wood grain texture prepared by the method according to any one of claims 1 to 18.