High-weather-resistance elastic sound-absorbing decorative plate, production line and production method thereof

Abstract

The application discloses a kind of high weathering elastic sound-absorbing decorative plate and its production line and production method, the plate material includes ultraviolet blocking weathering film, elastic layer, paste resin layer and porous metal plate in turn from top to bottom;The production line includes the confluence forming die arranged in turn along the direction of production line, cooling roller group, infrared radiation heater, cold press roller group and traction device, and the infrared radiation heater and cold press roller group are also provided with discharging roller between;The production method includes the following steps: porous metal plate drafting;Preparation paste resin layer and elastic layer;Radiation heating and preparation ultraviolet blocking decorative composite layer.The decorative plate prepared by the application integrates ultraviolet blocking performance, weathering performance, flame-retardant performance, sound insulation and sound absorption performance and elastic recovery performance, can meet the use requirements of different scenes, and does not occur interlayer separation in the use process, long service life, broad market prospect.

Description

Technical Field

[0001] This invention relates to the field of sound-absorbing panels, and in particular to a high weather-resistant elastic sound-absorbing decorative panel, production line, and production method. It is a waterproof, weather-resistant, sound-absorbing decorative panel or a post-processed board that can be used for building roofs, interior and exterior walls, and furniture surfaces. Background Technology

[0002] With the continuous advancement of technology, humans have the opportunity to make better choices for improving their clothing, food, housing, and transportation, such as color steel roof tiles for factory buildings, exterior wall panels, integrated exterior wall insulation decorative panels, container panels, and home decoration panels.

[0003] Existing technologies already include various functional boards, such as insulation boards, sound-absorbing boards, high-temperature resistant insulation boards, and waterproof boards. Furthermore, the materials used in these boards are diverse, including foamed cement, PVC, metal, and glass.

[0004] However, in the process of implementing the inventive technical solutions in the embodiments of this application, the inventors of this application discovered that the various materials and properties of the aforementioned sheet metal have at least the following technical problems:

[0005] Various types of boards typically have relatively limited functions, making it difficult to simultaneously meet comprehensive performance requirements such as rainproofing, weather resistance, sound insulation, resilience, and sound absorption and heat insulation. Decorative boards, in particular, are very prone to aging, brittleness, fading, and cracking during use due to sunlight, acid rain, and other factors. Their sound insulation and elasticity often fail to meet usage requirements, and defects such as delamination may even occur. Summary of the Invention

[0006] This invention provides a high weather-resistant, elastic sound-absorbing decorative panel, a production line, and a production method, which can solve the above-mentioned shortcomings of existing panels in the prior art.

[0007] To solve the above-mentioned technical problems, the present invention provides a high weather-resistant elastic sound-absorbing decorative panel, which comprises, from top to bottom, an ultraviolet-blocking weather-resistant film, an elastic layer, a paste resin layer and a porous metal plate.

[0008] The ultra-weather-resistant UV barrier film comprises the following components by weight: 30-55 parts of special resin raw material A, 10-25 parts of polyvinylpyrrolidone-acrylonitrile resin, 35-45 parts of polymethyl methacrylate, 2-5 parts of UV absorber, and 0.5-3 parts of antioxidant.

[0009] The special resin raw material A is prepared by the following method:

[0010] Under nitrogen protection and stirring conditions, add appropriate amounts of deionized water, 15-40 parts of butyl acrylate, 0.3-1.0 parts of ethylene glycol dimethacrylate, 10-40 parts of acrylonitrile, 10-30 parts of 4-methyl-α-methylstyrene, 5-35 parts of ethyl methacrylate, 2-8 parts of emulsifier, 2-6 parts of initiator, and 5-25 parts of polyvinyl alcohol to the reactor and react fully for 3-6 hours. After emulsion polymerization, the special resin raw material A powder is obtained by demulsification, flocculation, washing, centrifugation, drying, and sieving.

[0011] In a preferred embodiment of the present invention, the ultraviolet absorber is any one or a mixture of several of benzophenones, benzotriazoles, substituted acrylonitriles or triazines.

[0012] In a preferred embodiment of the present invention, the antioxidant is any one or a mixture of several of the following: phenolic antioxidant 1010, antioxidant 1076, antioxidant 1098, antioxidant 300, or distearate thiodipropionate.

[0013] In a preferred embodiment of the present invention, the elastic layer comprises the following components in parts by weight: 20-40 parts of polyvinyl chloride resin with a degree of polymerization of 1800-2200, 10-30 parts of polyvinylidene fluoride, 25-55 parts of elasticity reinforcing agent, 2-10 parts of plasticizer, 1-5 parts of calcium stearate, 1-4 parts of zinc stearate, 1-5 parts of rutile titanium dioxide, 1-6 parts of pigment, 1-3 parts of glyceryl stearate, and 1-8 parts of calcium carbonate.

[0014] In a preferred embodiment of the present invention, the elastic reinforcing agent comprises, by weight, a mixture of 20-40 parts of α-methylstyrene-pentyl acrylate-acrylonitrile copolymer resin, 10-30 parts of butyl acrylate powder, 10-30 parts of nitrile butadiene rubber powder, and 15-40 parts of chlorinated polyethylene powder.

[0015] In a preferred embodiment of the present invention, the paste resin layer comprises the following components in parts by weight: 35-60 parts of PVC paste resin with a degree of polymerization of 1000-1400, 10-40 parts of chloroacetic acid resin, 10-30 parts of nitrile rubber powder, 3-15 parts of liquid polyamide, 3-15 parts of terpene resin, 2-6 parts of dioctyl phthalate, 1-5 parts of dioctyl adipate, 3-8 parts of stabilizer, 0.2-0.6 parts of 3-aminopropyltriethoxysilane, and 1-3 parts of calcium carbonate.

[0016] In a preferred embodiment of the present invention, the porous metal plate has the following specifications: thickness 0.5-1.5 mm, circular holes, hole spacing of 10-100 mm, and hole diameter of 2-8 mm.

[0017] To solve the above-mentioned technical problems, the present invention provides a high weather-resistant elastic sound-absorbing decorative panel production line, comprising a confluence forming mold, a cooling roller group, an infrared irradiation heater, a cold pressing roller group, and a traction device arranged sequentially along the production line direction; wherein, the confluence forming mold has a through hole for the porous metal plate to pass through, a first flow channel for the melt of the paste resin layer to flow through, and a second flow channel for the melt of the elastic layer to flow through; the through hole horizontally penetrates the confluence forming mold along the production line direction, and the first flow channel is located below the second flow channel; a feeding roller is also provided between the infrared irradiation heater and the cold pressing roller group, on which a UV-blocking weather-resistant film roll is placed.

[0018] In a preferred embodiment of the present invention, a first air cooler is provided on one side of the cooling roller assembly, and a second air cooler is provided on one side of the cold pressing roller assembly.

[0019] To solve the above-mentioned technical problems, the present invention provides a method for producing a high weather-resistant, elastic sound-absorbing decorative panel, which uses the above-mentioned production line and includes the following steps:

[0020] (1) Porous metal plate stretching: The porous metal plate is passed through the through hole of the confluence forming mold and passes through the cooling roller group and the cold pressing roller group in sequence, and is pulled forward by the traction device;

[0021] (2) Molding the paste resin layer and the elastic layer: The raw materials of the paste resin layer and the elastic layer are melted into fluids, and then injected into the confluence molding mold from the first flow channel and the second flow channel respectively, and covered on the porous metal plate from bottom to top. After being rolled and cooled by the cooling roller group and the first air cooler, the paste resin layer and the elastic layer are formed on the porous metal plate respectively.

[0022] (3) Radiation heating: Turn on the infrared radiation heating device to heat and soften the paste resin layer and elastic layer on the porous metal plate, and uniformly coat the surface of the elastic layer with hot melt adhesive.

[0023] (4) Forming a high weather-resistant elastic sound-absorbing decorative panel: Unwind the UV-blocking weather-resistant film roll on the unwinding roller, so that the UV-blocking weather-resistant film is bonded to the elastic layer after being heated and softened in step (3) and bonded with the hot melt adhesive. Then, under the stretching of the traction device, they pass together through the cold pressure roller group for pressing and shaping to obtain the high weather-resistant elastic sound-absorbing decorative panel.

[0024] The beneficial effects of this invention are as follows: This invention provides a high weather-resistant elastic sound-absorbing decorative panel, production line, and production method. Through the structural design of the ultraviolet-blocking weather-resistant film, elastic layer, resin layer, and porous metal plate, as well as the design of the production line, the prepared decorative panel integrates waterproof and rainproof properties, weather resistance, flame retardant properties, sound insulation and absorption properties, and elastic recovery properties. It can meet the usage needs of different scenarios, and does not experience interlayer separation during use, has a long service life, and has broad market prospects. Attached Figure Description

[0025] Figure 1 This is a three-dimensional structural schematic diagram of a preferred embodiment of a high weather-resistant elastic sound-absorbing decorative panel of the present invention;

[0026] Figure 2 This is a schematic diagram of the production line for a high weather-resistant, elastic sound-absorbing decorative panel according to the present invention;

[0027] Figure 3 This is a schematic diagram of the cross-sectional structure of the confluence molding die shown.

[0028] The components in the attached diagram are labeled as follows:

[0029] 10. UV-blocking weather-resistant film; 20. Elastic layer; 30. Paste resin layer; 40. Porous metal plate; 50. Confluence molding die; 60. Cooling roller assembly; 70. Infrared irradiation heater; 80. Feeding roller; 90. Cold pressing roller assembly; 100. Hot melt adhesive; 110. First air cooler; 120. Second air cooler; 51. Through hole; 52. First flow channel; 53. Second flow channel. Detailed Implementation

[0030] The preferred embodiments of the present invention will now be described in detail with reference to the accompanying drawings, so that the advantages and features of the present invention can be more easily understood by those skilled in the art, thereby providing a clearer and more explicit definition of the scope of protection of the present invention.

[0031] Please see Figure 1-3 The embodiments of the present invention include:

[0032] This invention discloses a high weather-resistant elastic sound-absorbing decorative panel, which includes, from top to bottom, an ultraviolet-blocking weather-resistant film 10, an elastic layer 20, a paste resin layer 30, and a porous metal plate 40.

[0033] The UV-blocking weather-resistant film 10 comprises the following components by weight: 30-55 parts of special resin raw material A, 10-25 parts of polyvinylpyrrolidone-acrylonitrile resin, 35-45 parts of polymethyl methacrylate, 2-5 parts of UV absorber, and 0.5-3 parts of antioxidant; wherein the UV absorber is any one or a mixture of several of benzophenone, benzotriazole, substituted acrylonitrile, or triazine.

[0034] The antioxidant is any one or a mixture of several of the following: phenolic antioxidant 1010, antioxidant 1076, antioxidant 1098, antioxidant 300, or distearate alcohol thiodipropionate.

[0035] The method for preparing the UV-blocking and weather-resistant film is as follows:

[0036] (1) Weigh the special resin raw material A, polyvinylpyrrolidone-acrylonitrile resin, polymethyl methacrylate, ultraviolet absorber and antioxidant according to the formula, mix them and stir them thoroughly, and dry them at 110°C for 5 hours to obtain a dry mixture.

[0037] (2) The dried mixture obtained in step (1) is added to an extruder and formed by a flat calendering die to obtain the ultra-weather-resistant UV barrier film 10.

[0038] The special resin raw material A comprises the following components by weight: 15-40 parts butyl acrylate, 0.3-1.0 parts ethylene glycol dimethacrylate, 10-40 parts acrylonitrile, 10-30 parts 4-methylstyrene, 5-35 parts ethyl methacrylate, 2-8 parts emulsifier, 2-6 parts initiator, 5-25 parts polyvinyl alcohol, and 100 parts deionized water.

[0039] The UV-blocking weather-resistant film 10 has a certain elastic deformation capacity. When it is impacted by an external force, the film and the elastic bottom layer will sink inward without breaking, and can recover as the elastic layer rebounds, thereby improving the sound absorption and sound insulation performance and impact resistance of the entire board. At the same time, it has a certain buffering protection effect against human impact on the wall surface.

[0040] The elastic layer comprises the following components in parts by weight: 20-40 parts of polyvinyl chloride resin with a degree of polymerization of 1800-2200, 10-30 parts of polyvinylidene fluoride, 25-55 parts of elastic reinforcing agent, 2-10 parts of plasticizer, 1-5 parts of calcium stearate, 1-4 parts of zinc stearate, 1-5 parts of rutile titanium dioxide, 1-6 parts of colorant, 1-3 parts of glyceryl stearate, and 1-8 parts of calcium carbonate. The elastic reinforcing agent comprises a mixture of 20-40 parts of α-methylstyrene-pentyl acrylate-acrylonitrile copolymer resin, 10-30 parts of butyl acrylate powder, 10-30 parts of nitrile butadiene rubber powder, and 15-40 parts of chlorinated polyethylene powder.

[0041] In addition, color powder can be added to the elastic layer as needed to create a decorative effect, thereby giving the board decorative properties.

[0042] The paste resin layer comprises the following components in parts by weight: 35-60 parts of PVC paste resin with a degree of polymerization of 1000-1400, 10-40 parts of chloroacetic acid resin, 10-30 parts of nitrile rubber powder, 3-15 parts of liquid polyamide, 3-15 parts of terpene resin, 2-6 parts of dioctyl phthalate, 1-5 parts of dioctyl adipate, 3-8 parts of stabilizer, 0.2-0.6 parts of 3-aminopropyltriethoxysilane, and 1-3 parts of calcium carbonate.

[0043] The specifications of the porous metal plate are: thickness 0.5-1.5mm, circular holes, hole spacing of 10-100mm, and hole diameter of 2-8mm.

[0044] The present invention also discloses a production line for high weather-resistant elastic sound-absorbing decorative panels, including a confluence forming mold 50, a cooling roller group 60, an infrared irradiation heater 70, a feeding roller 80, a cold pressing roller group 90, and a traction device (not shown) arranged sequentially along the production line direction.

[0045] The confluence molding die 50 has a through hole 51 for the porous metal plate 40 to pass through, a first flow channel 52 for the melt of the resin paste layer 30 to flow through, and a second flow channel 53 for the melt of the elastic layer 20 to flow through. The through hole 51 horizontally penetrates the confluence molding die 50 along the direction of the production line. The first flow channel 52 is located below the second flow channel 53. The outlet of the first flow channel 52 communicates with the porous metal plate 40 before the outlet of the second flow channel, thereby ensuring that the melt of the resin paste layer 30 is directly coated on the porous metal plate 40, and the melt of the elastic layer 20 is coated on the resin paste layer 30.

[0046] Each cooling roller group 60 comprises two cooling rollers, symmetrically installed vertically, to perform roll cooling on the porous metal plate 40 flowing between the two cooling rollers and the resin paste layer 30 and elastic layer 20 thereon. The number of cooling roller groups 60 can be set to two or more. Additionally, the production line includes a first air cooler 110, arranged on the side of the cooling roller group 60 facing the traction direction, for further cooling of the decorative panel after roll cooling, thereby accelerating the cooling rate of the resin paste layer 30 and elastic layer 20.

[0047] The infrared irradiation heater 70 is arranged vertically downward with the heating port to heat and soften the resin layer 30 and elastic layer 20 on the porous metal plate 40, so as to facilitate effective bonding between the ultraviolet barrier weather-resistant roll material and the elastic layer 20 in the next process.

[0048] The feeding roller 80 is arranged on the upper side between the infrared irradiation heater 70 and the cold pressing roller group 90, and holds the ultraviolet-blocking weather-resistant roll material (i.e. the ultraviolet-blocking weather-resistant film 10 mentioned above).

[0049] The cold press roller assembly 90 comprises two cold press rollers arranged symmetrically vertically to perform roll pressing cooling on the porous metal plate 40 flowing between the two cold press rollers and its surface layer 30, elastic layer 20, and UV-blocking weather-resistant film 10. Additionally, the production line includes a second air cooler 120, which is arranged on the side of the cold press roller assembly 90 facing the traction direction, for further cooling of the decorative panel after roll pressing cooling.

[0050] Example 1

[0051] I. Preparation of Special Resin A

[0052] Under nitrogen protection and stirring conditions, 100 parts of deionized water, 15 parts of butyl acrylate, 0.6 parts of ethylene glycol dimethacrylate, 30 parts of acrylonitrile, 15 parts of 4-methyl-α-methylstyrene, 25 parts of ethyl methacrylate, 5 parts of emulsifier, 3 parts of initiator, and 20 parts of polyvinyl alcohol were added to the reactor and reacted for 5 hours. After emulsion polymerization, the mixture was demulsified and flocculated, washed with water, centrifuged, dried, and sieved to obtain special resin raw material A powder.

[0053] The special resin raw material A uses 4-methyl-α-methylstyrene, which helps to improve the heat resistance and melt flow of the resin; it uses ethylene glycol dimethacrylate, which acts as a solubilizer and improves the polymerization efficiency; and it uses ethyl methacrylate and butyl acrylate copolymerization to adjust the elasticity and plasticity of the polymer particles.

[0054] II. Preparation of UV-blocking and weather-resistant films

[0055] (1) Weigh 50 parts of the special resin raw material A prepared by the above method, 15 parts of polyvinylpyrrolidone-acrylonitrile resin, 40 parts of polymethyl methacrylate, 3 parts of benzophenone-based ultraviolet absorber and 10101 parts of antioxidant, mix them and stir them thoroughly, and dry them in a 110℃ forced-air drying oven for 5 hours to obtain a dried mixture.

[0056] (2) The dried mixture obtained in step (1) is added to an extruder, and the extruded molten material is formed by a flat calendering die to obtain the ultra-weather-resistant UV barrier film 10.

[0057] By blending polyvinylpyrrolidone-acrylonitrile resin and polymethyl methacrylate with special resin raw material A, the prepared film not only possesses the high light transmittance and high gloss of PMMA, but also has better elasticity and stress deformation recovery ability, and improves the good compatibility between the film interface and the binder.

[0058] By adding UV absorbers and antioxidants, the film is given excellent weather resistance, which fully protects the composite layer under the ultra-weather-resistant UV barrier film, preventing it from aging due to sunlight and acid rain. It can withstand aging for more than 25 years without significant discoloration, while also ensuring the good processing performance of the blended resin.

[0059] Example 2

[0060] The difference from Example 1 is that, in the preparation process of the UV-blocking weather-resistant film, 35 parts of special resin raw material A, 15 parts of polyvinylpyrrolidone-acrylonitrile resin, 40 parts of polymethyl methacrylate, 3 parts of benzophenone-based UV absorber, and 10101 parts of antioxidant are added.

[0061] Example 3

[0062] The difference from Example 1 is that, in the preparation process of the UV-blocking weather-resistant film, 40 parts of special resin raw material A, 15 parts of polyvinylpyrrolidone-acrylonitrile resin, 40 parts of polymethyl methacrylate, 3 parts of benzophenone-based UV absorber and 10101 parts of antioxidant are added.

[0063] Comparative Example 1

[0064] Compared with Example 1, in the preparation process of the UV-blocking weather-resistant film, 60 parts of special PMMA resin, 35 parts of ABS resin, 3 parts of benzophenone-based UV absorber and 10101 parts of antioxidant are added.

[0065] Comparative Example 2

[0066] Compared with Comparative Example 1, in the preparation process of the UV-blocking weather-resistant film, 40 parts of special PMMA resin, 15 parts of polyvinylpyrrolidone-acrylonitrile resin and 40 parts of ASA were added.

[0067] The accelerated aging performance of the ultra-weather-resistant UV barrier films prepared in Examples 1-3 and Comparative Examples 1 and 2 was tested using the accelerated photoaging test standard GB / T 16422.2-2014. The results are shown in Table 1 below. ΔE represents the degree of discoloration of the material after aging, reflecting its anti-aging performance. For the same aging time, the smaller the test result ΔE, the better the material's anti-aging performance.

[0068] Table 1

[0069]

[0070] The test results show that the transmittance of the UV-blocking weather-resistant film prepared with special resin raw material A is comparable to that of the film prepared with PMMA. However, its elasticity, especially after 12,000 hours of xenon lamp aging, is still significantly better than that of the film modified by blending PMMA and ASA. It has better elasticity and stress deformation recovery ability. The film interface has good compatibility with the adhesive, and the film has good weather resistance. By adding UV absorbers and antioxidants, super weather resistance is achieved, which fully protects the composite layer under the ultra-weather-resistant UV-blocking film from sunlight and acid rain. The film has a aging resistance of more than 25 years without significant discoloration.

[0071] Example 4

[0072] The UV-blocking weather-resistant film prepared in Example 3 above was used as a UV-blocking weather-resistant roll material for later use. Then, the formulation design and molding of the elastic layer 20 and the paste resin layer 30 were carried out, and the entire UV-blocking ultra-weather-resistant elastic sound-absorbing decorative panel was prepared.

[0073] Specifically, the elastic layer 20 comprises the following components in parts by weight: 35 parts of polyvinyl chloride resin (degree of polymerization 2100), 25 parts of polyvinylidene fluoride, 40 parts of elastic reinforcing agent, 6 parts of plasticizer (a mixture of styrene-acrylonitrile, acrylate rubber copolymer resin, acrylate rubber powder, nitrile rubber powder, and chlorinated polyethylene powder in a mass ratio of 15:25:20:10:30), 5 parts of calcium-zinc stabilizer, 1 part of glyceryl stearate, and 2 parts of calcium carbonate. Additionally, 3-5 parts of colorant may be added to the elastic layer 20 to produce a monochromatic decorative effect.

[0074] The paste resin layer 30 comprises the following components in parts by weight: 45 parts of PVC paste resin (degree of polymerization 1200), 22 parts of chloroacetic acid resin, 10 parts of nitrile rubber, 5 parts of liquid polyamide, 5 parts of terpene resin, 5 parts of dioctyl phthalate, 2 parts of dioctyl adipate, 3 parts of calcium stearate, 2 parts of zinc stearate, and 3 parts of calcium carbonate.

[0075] The porous metal plate 40 is made of galvanized steel with a hole diameter of 3mm, a hole spacing of 10mm, and a plate thickness of 0.8mm. The design and use of the porous metal plate 40 effectively improves the structural strength of the entire decorative panel. Furthermore, the porous design allows the resin layer 30 to pass through the holes in the porous metal plate 40 in a molten state, thereby improving the adhesion between the resin layer 30 and the porous metal plate 40. This ensures the strong interlayer adhesion of the overall decorative panel under secondary deformation processing such as bending after appropriate heating, preventing interlayer separation. The high weather-resistant elastic sound-absorbing decorative panel provided by this invention can be further bent into corrugated tiles for use as weather-resistant, waterproof, and sound-absorbing roofing tiles.

[0076] The production method of the above-mentioned high weather-resistant and elastic sound-absorbing decorative panel specifically includes the following steps:

[0077] (1) Porous metal plate stretching: The porous metal plate 40 is passed through the through hole 51 of the confluence forming mold 50 and passes through the cooling roller group 60 and the cold pressing roller group 90 in sequence, and is pulled forward at a constant speed on the transmission roller by the traction device.

[0078] (2) Forming the paste resin layer: Weigh each component according to the formula of the paste resin layer, mix and dry, then add the dried mixture into a single screw extruder, set the extrusion temperature to 160°C, extrude the mixture in a molten state and feed it into the first flow channel 52 of the confluence molding die 50, the molten material flows out from the outlet of the first flow channel 52 and covers the porous metal plate 40 to form the paste resin layer;

[0079] Molding the elastic layer: Weigh each component according to the formula of the elastic layer, mix and dry them, and then add the dried mixture into the counter-rotating twin-screw extruder. Set the extrusion temperature to 160°C, extrude the mixture in a molten state, and feed it into the second flow channel 53 of the confluence molding die 50. The molten material flows out from the outlet of the second flow channel 53 and covers the paste resin layer to form an elastic layer.

[0080] Then, the porous metal plate, which is covered with a resin layer and an elastic layer from bottom to top, is cooled by the rolling of the cooling roller group 60 and the cooling of the first air cooler 110 under traction. The resin layer and the elastic layer are cooled, cured and bonded together.

[0081] (3) Radiation heating: Turn on the infrared radiation heating device with a heating power of 6kW to heat and soften the paste resin layer and elastic layer on the porous metal plate, and uniformly coat the surface of the elastic layer with hot melt adhesive 100.

[0082] (4) Forming a high weather-resistant elastic sound-absorbing decorative panel: Unwind the UV-blocking weather-resistant film roll on the unwinding roller, so that the UV-blocking weather-resistant film is attached to the surface of the elastic layer in step (3), and then pass through the cold pressure roller group together under the stretching of the traction device for pressing and shaping, and finally obtain the high weather-resistant elastic sound-absorbing decorative panel.

[0083] Example 5

[0084] The difference from Example 4 is that the paste resin layer 30 comprises the following components in parts by weight: 25 parts of PVC paste resin (degree of polymerization 1200), 30 parts of chloroacetic acid resin, 20 parts of nitrile rubber, 6 parts of liquid polyamide, 3 parts of terpene resin, 4 parts of dioctyl phthalate, 4 parts of dioctyl adipate, 2 parts of calcium stearate, 4 parts of zinc stearate, and 2 parts of calcium carbonate.

[0085] Example 6

[0086] The difference from Example 4 is that the paste resin layer 30 comprises the following components in parts by weight: 35 parts of PVC paste resin (degree of polymerization 1200), 20 parts of chloroacetic acid resin, 18 parts of nitrile rubber, 3 parts of liquid polyamide, 8 parts of terpene resin, 3 parts of dioctyl phthalate, 5 parts of dioctyl adipate, 3 parts of calcium stearate, 2 parts of zinc stearate, and 2 parts of calcium carbonate.

[0087] Comparative Example 3

[0088] The difference from Example 4 is that the polyvinyl chloride resin in the elastic layer 20 is replaced with an equal amount of ethylene propylene diene monomer (EPDM) rubber.

[0089] The high weather-resistant elastic sound-absorbing decorative panels prepared in Examples 4-6 and Comparative Example 2 were subjected to performance tests. The specific test contents and methods are as follows:

[0090] Interlayer peel strength test: The test standard is based on ASTM D1876. The T-type peel strength test is performed on a universal testing machine with a tensile rate of 100 mm / min. The test is stopped when the sample is completely peeled off, and the maximum load and average load are recorded.

[0091] Rain noise insulation test: The test standard is GB-T 19889.18-2017 Measurement of sound insulation of buildings and building components - Part 18: Laboratory measurement of rain noise insulation of building components. A comparative test was conducted using 0.8mm color steel plate for the noise insulation test.

[0092] Flame retardant performance test: The flame retardant performance test shall be conducted in accordance with the UL94HB flame retardant rating test standard.

[0093] The test results are shown in Table 2 below. The thickness of the test sample was 5.0 mm (the same thickness facilitates the comparison of results).

[0094] Table 2

[0095]

[0096]

[0097] As shown in Table 2, compared with Comparative Example 3, both the elastic layer and the paste resin layer contain polyvinyl chloride resin, which can effectively improve the overall structural strength of the weather-resistant elastic sound-absorbing decorative panel and effectively improve the anti-delamination performance. Moreover, both the elastic layer and the paste resin layer contain polyvinyl chloride resin, which has better flame retardant performance and can provide better flame retardant protection for the protected object.

[0098] Comparison with the rain noise test results of a 0.8mm thick single-layer color steel plate (medium) shows that, under the same medium rain intensity, the high weather-resistant elastic sound-absorbing decorative panel of this invention, due to the design of the resin layer 30, elastic layer 20 and ultraviolet barrier weather-resistant film 10, can play a role in noise reduction and sound insulation, greatly reducing indoor noise to 44.8 to 41.6dB, which exceeds the quietness standard of a five-star hotel.

[0099] Since both the elastic layer 20 and the resin paste layer 30 contain PVC resin, this invention improves the compatibility between them, facilitating a strong, integrated hot-pressing process before bonding to the UV-blocking weather-resistant film 10 using hot melt adhesive 100, thus simplifying the bonding process. Furthermore, because PVC is a chlorine-containing material with self-extinguishing properties and excellent flame-retardant and fire-resistant performance, even if ignited, the fire will gradually subside as it reaches the elastic layer 20, providing flame-retardant protection to the attached object and improving safety.

[0100] The high weather-resistant, elastic, sound-absorbing decorative panel of the present invention has a multi-layer structure comprising a porous metal plate 40, a resin paste layer 30, an elastic layer 20, and a UV-blocking weather-resistant film 10. It possesses rigidity, high density, elasticity, flexibility, resilience, and flame retardancy. In particular, the UV-blocking weather-resistant film 10 and the elastic layer 20 can fully deform and absorb energy, providing excellent buffering effects against impacts and vibrations. It also has excellent sound absorption and sound insulation properties against impact sounds and airborne sounds. The UV-blocking weather-resistant film 10 endows the decorative panel with excellent properties such as resistance to light aging, acid rain, and weathering.

[0101] Because the high weather-resistant elastic sound-absorbing decorative panel of the present invention has high interlayer peel strength, the UV-blocking weather-resistant film and elastic layer have sufficient deformation and ductility, the resin layer and the metal plate are tightly bonded in a porous manner, and the cold bending process will not cause delamination, thus fully ensuring the quality of the cold bending process, the panel of the present invention can also be bent into a water ripple pattern, such as 820 type and 970 type roofing tiles.

[0102] The high weather-resistant, elastic sound-absorbing decorative panel prepared by this invention through the design of the formula, production line, and production method has the following advantages:

[0103] 1. Produce a multi-functional board that can be processed by secondary molding, which includes a multi-layer structure of metal plate, resin paste layer, elastic layer and UV barrier weather-resistant film. It combines the excellent performance of each layer into one, with super weather resistance with high UV barrier, B1 flame retardant performance, good sound insulation / sound absorption function, elastic recovery performance after external force, good thermal insulation performance and rigidity strength, to meet the needs of a variety of applications.

[0104] 2. The UV barrier weatherproof film is an ultra-weather-resistant UV barrier film with a certain elastic deformation capacity. After being impacted by external force, it will not break as the underlying elastic layer indents and can recover as the elastic layer rebounds. It is beneficial for impact sound absorption and energy absorption, and can be used for sports venue maintenance to reduce impact injuries to athletes.

[0105] 3. Both the paste resin layer and the elastic layer are based on PVC resin. Because they both contain PVC resin, they have good compatibility, which facilitates hot-pressing and bonding them into a strong whole. This saves on adhesives, simplifies the process, and effectively ensures resistance to sunlight and acid rain corrosion, as well as excellent weather resistance. Furthermore, because the porous metal plate has a dense network of pores, the molten paste resin layer can penetrate the pores of the metal plate and bond firmly to it. This fully ensures that the layers of the entire board are firmly bonded together without separation even after the porous metal plate and the UV-blocking weather-resistant film have undergone secondary forming and deformation processes such as bending after appropriate heating.

[0106] 4. Both the resin paste layer and the elastic layer are made of PVC chlorine-containing materials, which have self-extinguishing function after the flame is removed. No additional flame retardant is required. They have excellent flame retardant and fire-resistant properties and low overall cost.

[0107] The above description is merely an embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent structural or procedural transformations made based on the content of the present invention's specification and drawings, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of the present invention.

Claims

1. A high weather-resistant, elastic sound-absorbing decorative panel, characterized in that, From top to bottom, it includes a UV-blocking weather-resistant film, an elastic layer, a paste resin layer, and a porous metal plate; The UV-blocking weather-resistant film comprises the following components by weight: 30-55 parts of special resin raw material A, 10-25 parts of polyvinylpyrrolidone-acrylonitrile resin, 35-45 parts of polymethyl methacrylate, 2-5 parts of UV absorber, and 0.5-3 parts of antioxidant. The special resin raw material A is prepared by the following method: Under nitrogen protection and stirring conditions, 100 parts of deionized water, 15-40 parts of butyl acrylate, 0.3-1.0 parts of ethylene glycol dimethacrylate, 10-40 parts of acrylonitrile, 10-30 parts of 4-methyl-α-methylstyrene, 5-35 parts of ethyl methacrylate, 2-8 parts of emulsifier, 2-6 parts of initiator, and 5-25 parts of polyvinyl alcohol are added to the reactor and reacted for 3-6 hours. After emulsion polymerization, the mixture is sequentially demulsified, flocculated, washed, centrifuged, dried, and sieved to obtain the special resin raw material A powder. The elastic layer comprises the following components in parts by weight: 20-40 parts of polyvinyl chloride resin with a degree of polymerization of 1800-2200, 10-30 parts of polyvinylidene fluoride, 25-55 parts of elasticity reinforcing agent, 2-10 parts of plasticizer, 1-5 parts of calcium stearate, 1-4 parts of zinc stearate, 1-5 parts of rutile titanium dioxide, 1-6 parts of colorant, 1-3 parts of glyceryl stearate, and 1-8 parts of calcium carbonate; the elasticity reinforcing agent comprises a mixture of 20-40 parts of α-methylstyrene-pentyl acrylate-acrylonitrile copolymer resin, 10-30 parts of butyl acrylate powder, 10-30 parts of nitrile butadiene rubber powder, and 15-40 parts of chlorinated polyethylene powder; The paste resin layer comprises the following components in parts by weight: 35-60 parts of PVC paste resin with a degree of polymerization of 1000-1400, 10-40 parts of chloroacetic acid resin, 10-30 parts of nitrile rubber powder, 3-15 parts of liquid polyamide, 3-15 parts of terpene resin, 2-6 parts of dioctyl phthalate, 1-5 parts of dioctyl adipate, 3-8 parts of stabilizer, 0.2-0.6 parts of 3-aminopropyltriethoxysilane, and 1-3 parts of calcium carbonate.

2. The high weather-resistant elastic sound-absorbing decorative panel according to claim 1, characterized in that, The ultraviolet absorber is any one or a mixture of several of benzophenones, benzotriazoles, substituted acrylonitriles, or triazines.

3. The high weather-resistant elastic sound-absorbing decorative panel according to claim 2, characterized in that, The antioxidant is any one or a mixture of several of the following: phenolic antioxidant 1010, antioxidant 1076, antioxidant 1098, antioxidant 300, or distearate alcohol thiodipropionate.

4. The high weather-resistant elastic sound-absorbing decorative panel according to claim 1, characterized in that, The specifications of the porous metal plate are: thickness 0.5-1.5mm, circular holes, hole spacing of 10-100mm, and hole diameter of 2-8mm.

5. A production line for a high weather-resistant, elastic sound-absorbing decorative panel as described in any one of claims 1-4, characterized in that, The assembly includes a confluence forming mold, a cooling roller assembly, an infrared irradiation heater, a cold pressing roller assembly, and a traction device arranged sequentially along the production line direction. The confluence forming mold has a through hole for the porous metal plate to pass through, a first flow channel for the melt of the paste resin layer to flow through, and a second flow channel for the melt of the elastic layer to flow through. The through hole horizontally penetrates the confluence forming mold along the production line direction, and the first flow channel is located below the second flow channel. A feeding roller is also provided between the infrared irradiation heater and the cold pressing roller assembly, on which a UV-blocking weather-resistant film roll is placed.

6. The production line for high weather-resistant, elastic sound-absorbing decorative panels according to claim 5, characterized in that, A first air cooler is provided on one side of the cooling roller assembly, and a second air cooler is provided on one side of the cold pressing roller assembly.

7. A method for producing a high weather-resistant, elastic sound-absorbing decorative panel, characterized in that, The production line according to claim 6 includes the following steps: (1) Porous metal plate stretching: The porous metal plate is passed through the through hole of the confluence forming mold and passes through the cooling roller group and the cold pressing roller group in sequence, and is pulled forward by the traction device; (2) Molding the paste resin layer and the elastic layer: The raw materials of the paste resin layer and the elastic layer are melted into fluids, and then injected into the confluence molding mold from the first flow channel and the second flow channel respectively, and covered on the porous metal plate from bottom to top. After being rolled and cooled by the cooling roller group and the first air cooler, the paste resin layer and the elastic layer are formed on the porous metal plate respectively. (3) Radiation heating: Turn on the infrared radiation heater to heat and soften the paste resin layer and elastic layer on the porous metal plate, and uniformly coat the surface of the elastic layer with hot melt adhesive. (4) Forming a high weather-resistant elastic sound-absorbing decorative panel: Unwind the UV-blocking weather-resistant film roll on the unwinding roller, so that the UV-blocking weather-resistant film is bonded to the elastic layer after being heated and softened in step (3) and bonded with the hot melt adhesive. Then, under the stretching of the traction device, they pass together through the cold pressure roller group for pressing and shaping to obtain the high weather-resistant elastic sound-absorbing decorative panel.

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