A smooth decorative panel

Abstract

A smooth decorative board, which comprises a base layer and a smooth layer provided on the base layer. The smooth layer is made of a PET aluminized film coated with melamine-modified polyurethane. The thickness of the smooth layer is 0.11 mm to 0.15 mm. The base layer is made of kraft paper and impregnated with modified phenolic resin. The thickness of the base layer is 0.1 mm to 0.15 mm. The melamine-modified polyurethane is mixed and modified by a modifier with a weight percentage of 11% to 18% and the reacted melamine and polyurethane. The modifier is flexible amine D-230. The modified phenolic resin is mixed and modified by a plasticizer with a weight percentage of 7% to 10% and phenolic resin, and the plasticizer is phthalate. This smooth decorative board will not crack or warp at the edges whether in a dry environment or a humid environment. Moreover, due to the use of the PET aluminized film, the smoothness and flexibility are improved, facilitating cleaning and also increasing the lifespan of the overall decoration.

Description

Technical Field

[0001] The present invention relates to the technical field of plate manufacturing, in particular to a smooth decorative plate. Background Art

[0002] Decorative panels are widely used in architectural decoration and furniture manufacturing. Existing decorative panels are primarily made of wood, but they are expensive and require significant logging, which is not conducive to environmental protection. Furthermore, the paint and gluing processes required during use are also unfavorable to the environment and generate polluting gases.

[0003] To address these issues, existing technologies have used decorative panels made by impregnating multiple layers of paper with glue, then hot-pressing them into shape and then attaching decorative paper to replace existing wood panels. However, existing decorative panels lack stain resistance and are difficult to clean. To achieve easier cleaning, a smooth film, such as a PE film coating or wood veneer, is often applied directly to the existing panels. These films are susceptible to corrosion over time, resulting in peeling and cracking, which affects both the aesthetics and the overall lifespan of the decorative panels. Summary of the Invention

[0004] In view of this, it is necessary to provide a smooth decorative panel to solve the above problems.

[0005] A smooth decorative panel comprises a base layer and a smooth layer disposed on the base layer. The smooth layer is made of a PET aluminized film coated with melamine-modified polyurethane. The thickness of the smooth layer ranges from 0.11 mm to 0.15 mm. The base layer is made of kraft paper and impregnated with a modified phenolic resin. The thickness of the base layer ranges from 0.1 mm to 0.15 mm. The melamine-modified polyurethane is modified by mixing 11% to 18% by weight of a modifier with the reacted melamine and polyurethane. The modifier is flexible amine D-230. The modified phenolic resin is modified by mixing 7% to 10% by weight of a plasticizer with the phenolic resin; the plasticizer is a phthalate.

[0006] Furthermore, the thickness of the smooth decorative panel is less than or equal to 0.4 mm.

[0007] Furthermore, the reaction of melamine and polyurethane is carried out at a constant temperature of 80°C to 120°C.

[0008] Furthermore, the coating amount of the PET aluminized film is 10g / m 2 ~20g / m 2 .

[0009] Furthermore, the weight percentage of the flexible amine D-230 is 16%.

[0010] Furthermore, the weight percentage of the phthalate ester is 9%.

[0011] Furthermore, the smooth decorative board is formed through a hot pressing process.

[0012] Compared with the prior art, the smooth decorative board provided by the present invention controls the thickness of the smooth decorative board below 0.35 mm by selecting the materials used for the base layer and the smooth layer and designing the impregnating solution. Moreover, it will not crack or warp at the edges whether in a dry environment or a humid environment. Also, due to the use of the PET aluminized film, the smoothness and flexibility are improved, facilitating cleaning and also enhancing the lifespan of the overall decoration. Specific Embodiments

[0013] The following further elaborates on the specific embodiments of the present invention. It should be understood that the specific embodiments described herein are only examples and are not used to limit the protection scope of the present invention.

[0014] The smooth decorative board includes a base layer and a smooth layer provided on the base layer. The base layer is made of kraft paper. Specifically, the base layer may include multiple layers of kraft paper, and then the one or more layers of kraft paper are impregnated with modified phenolic resin. Since the thickness of the smooth decorative board itself is limited, that is, the thickness of the entire smooth decorative board is less than or equal to 0.4 mm, the thickness of the base layer should be set between 0.1 mm and 0.15 mm, otherwise it will affect the thickness of other structural layers, such as the smooth layer. When the thickness of the base layer is between 0.1 mm and 0.15 mm, in order to achieve the purpose of non-cracking, therefore, the improvement of its impregnating liquid becomes a necessary condition to achieve this purpose. The impregnating liquid used to impregnate the base layer is modified phenolic resin. The modified phenolic resin is obtained by mixing and modifying a plasticizer with a weight percentage of 7% - 10% and phenolic resin. The plasticizer is phthalate. The phenolic resin is also called bakelite, also known as bakelite powder, which is a colorless or light yellowish-brown transparent substance, and it is resistant to weak acids and weak bases. It is formed by the condensation reaction of phenol and formaldehyde under the action of an acidic or alkaline catalyst to produce phenolic resin. When modifying the phenolic resin, the modifier used is a plasticizer, and the plasticizer is phthalate. The phthalate, also known as phthalic acid ester, is a general term for esters formed by phthalic acid. It is mainly used in PVC materials to change PVC from a hard plastic to an elastic plastic, acting as a plasticizer. In the present invention, the content of the phthalate should be strictly controlled, and its weight percentage must be 7% - 10%. Preferably, the weight percentage of the phthalate is 9%. Due to the properties of the phthalic acid, if the usage amount is too much, the strength requirements of the smooth decorative board cannot be achieved, even though it has the function of the additional layer. If the usage amount is too little, the flexibility requirements of the smooth decorative board cannot be achieved, that is, the purpose of non-cracking cannot be achieved. Therefore, by modifying the phenolic resin with the phthalate, the base layer impregnated with the kraft paper can maintain its strength and have appropriate flexibility, thus facilitating the achievement of the purpose of non-cracking of the smooth decorative board.

[0015] The smooth layer is made of a PET (Polyethylene terephthalate) aluminized film coated with melamine-modified polyurethane. The thickness of the smooth layer is 0.11 mm to 0.15 mm. It is conceivable that various patterns meeting user requirements can also be provided on the PET aluminized film to meet the user's aesthetic requirements. The PET aluminized film itself is an existing technology, which is a barrier film formed by depositing a thin layer of aluminum atoms on a high-quality PET film through a vacuum aluminizing process. However, in order to be compounded with the base layer and not crack or warp during long-term use, melamine-modified polyurethane should be coated on the PET aluminized film before lamination. The melamine-modified polyurethane is a mixture of a modifier with a weight percentage of 11% - 18% and reacted melamine and polyurethane. The modifier is flexible amine D-230. The flexible amine D-230, also known as polyetheramine (PEA), is a polymer with a polyether structure in the main chain and an amine group as the terminal active functional group, which is obtained by ammoniating polyethylene glycol, polypropylene glycol, or ethylene glycol / propylene glycol copolymer under high temperature and high pressure. In the present invention, the flexible amine D-230 is used as a flexible curing agent. Melamine and polyurethane themselves are an existing technology and will not be elaborated here. When melamine and polyurethane react, melamine-polyurethane resin is formed.

[0016] When the melamine-polyurethane is modified with the flexible amine D-230, the mixture will not only have the properties of the melamine-polyurethane itself, but also have good flexibility and heat resistance, and at the same time have the adhesiveness of the polyurethane itself, so that the decorative board can not only ensure flexibility and heat resistance, but also improve the adhesiveness between the PET aluminized film and the base layer, preventing cracking or warping. And good heat resistance can prevent the cracking phenomenon caused by long-term use. However, due to the limitation of the total thickness of the smooth decorative board, the thickness of the decorative layer is only 0.11 mm to 0.15 mm. Therefore, in order to balance the strength and flexibility of the smooth layer, the modified melamine polyurethane is a mixture of a modifier with a weight percentage of 11% - 18% and reacted melamine and polyurethane, so that the strength, flexibility, and adhesiveness of the smooth layer of the smooth decorative board suitable for this thickness size can be obtained. In this embodiment, the weight percentage of the flexible amine D-230 is 8%.

[0017] After impregnating the above-mentioned base layer and the smooth layer coated with the modified melamine polyurethane respectively, put them into a hot press and form them through a hot pressing process to make the smooth decorative board. The thickness of the made smooth decorative board is less than or equal to 0.4 mm.

[0018] The following are the test methods and test results.

[0019] First is the surface heat and cold cycle resistance performance test, which is used to test the resistance ability of the smooth decorative board to repeated temperature changes. The test instruments and materials include:

[0020] A blast drying oven that can maintain a temperature of 80 degrees;

[0021] A refrigerator that can maintain a temperature of minus 25 degrees;

[0022] Ethanol with a volume fraction of 95, industrial grade;

[0023] Degreased gauze.

[0024] Test procedure: Wipe the surface of the smooth decorative board clean with a little ethanol dipped in degreased gauze and let it dry. Place the test piece in a drying oven at a temperature of 80 degrees for 120 minutes, and then place it in a refrigerator at a temperature of minus 20 degrees for 120 minutes as a cycle. After 2 such cycles, place it at room temperature for more than 1 hour.

[0025] Finally, under natural light, observe the surface condition of the smooth decorative board from any angle with normal vision.

[0026] Secondly, conduct the surface cracking resistance performance test, which is used to test whether cracks will appear on the smooth decorative board at a temperature of 70 degrees. The test instruments and materials include:

[0027] A blast drying oven that can maintain a temperature of 70 degrees;

[0028] A hand-held magnifying glass with a magnification of 6 times;

[0029] Illumination equipment with an illuminance of 800 lx to 1000 lx.

[0030] Place the smooth decorative board in the blast drying oven for heat treatment for 24 hours, then take out the smooth decorative board and place it in an environment with a temperature of 23 degrees and a humidity of 50% for 24 hours.

[0031] Under natural light, observe the surface condition of the test piece from any angle with normal vision, and observe the surface condition of the smooth decorative board with a magnifying glass with a magnification of 6 times under the illumination equipment with an illuminance of 800 lx to 1000 lx.

[0032] Test results

[0033]

[0034] Compared with the prior art, the smooth decorative board provided by the present invention controls the thickness of the smooth decorative board below 0.35 mm by selecting the materials used for the base layer and the smooth layer and designing the impregnating solution. Moreover, it will not crack or warp at the edges whether in a dry environment or a humid environment. And due to the use of the PET aluminized film, the smoothness and flexibility are improved, which facilitates cleaning and can also extend the service life of the overall decoration.

[0035] The above are only the preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent replacements, and improvements made within the spirit and principles of the present invention shall be included within the protection scope of the present invention.

Claims

1. A smooth decorative board, characterized in that: The smooth decorative board comprises a base layer and a smooth layer disposed on the base layer. The smooth layer is made of a PET aluminized film coated with melamine-modified polyurethane. The thickness of the smooth layer is 0.11 mm to 0.15 mm. The base layer is made of kraft paper and impregnated with modified phenolic resin. The thickness of the base layer is 0.1 mm to 0.15 mm. The melamine-modified polyurethane is obtained by mixing and modifying a modifier with a weight percentage of 11% to 18% with the reacted melamine and polyurethane. The modifier is flexible amine D-230. The modified phenolic resin is obtained by mixing and modifying a plasticizer with a weight percentage of 7% to 10% with phenolic resin. The plasticizer is phthalate. The thickness of the smooth decorative board is less than or equal to 0.4 mm.

2. The smooth decorative board according to claim 1, wherein: The reaction of the melamine and polyurethane is carried out at a constant temperature of 80°C to 120°C.

3. The smooth decorative board according to claim 1, wherein: The coating amount of the PET aluminized film is 10 g / m 2 ~20 g / m 2 .

4. The smooth decorative board according to claim 1, characterized in that: The weight percentage of the flexible amine D-230 is 16%.

5. The smooth decorative board according to claim 1, characterized in that: The weight percentage of the phthalate is 9%.

6. The smooth decorative board according to claim 1, characterized in that: The smooth decorative board is formed through a hot pressing process.

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