A plate with 3D texture structure, preparation method and application thereof

Abstract

The present invention belongs to the technical field of decorative boards, and in particular, relates to a board with a 3D texture structure, a preparation method and an application, wherein the board includes at least a substrate, a pattern layer, a wear-resistant layer and a topcoat layer from bottom to top; the wear-resistant layer includes a thickness adjustment layer and a texture layer located above the thickness adjustment layer, the texture layer includes a base portion and a three-dimensional portion, the three-dimensional portion is located above the base portion, the pattern layer includes a plurality of connected or unconnected wood grain-shaped lines, the three-dimensional portion includes a plurality of connected or unconnected wood grain-shaped grooves, at least part of the grooves correspond to the lines in one or more of the arrangement position, length or width, and at least part of the top of the topcoat layer is lower than the upper surface of the three-dimensional portion. The board of the present invention provides excellent wear resistance, and the formed 3D texture has better clarity, better touch feel and better visual effect.

Description

Technical Field

[0001] The present invention belongs to the technical field of decorative plates, and in particular relates to a plate with a 3D texture structure, a preparation method and an application thereof. Background Art

[0002] In the decorative board industry, the formation of a pattern structure with a 3D texture effect on the surface of the substrate is currently mainly achieved through the following two methods.

[0003] First, use printing and stacking on a flat coating to create a raised three-dimensional effect.

[0004] Related prior art, such as CN109653465A discloses a 3D effect PVC decorative board and its 3D printing production method, the PVC decorative board includes a PVC board substrate, and on the PVC board substrate, there are UV primer layer, UV white paint layer, pattern layer, UV wear-resistant paint layer, concave-convex effect layer, and UV topcoat layer from bottom to top. The UV white paint layer has 2 layers, the UV wear-resistant paint layer has 3 layers, and the UV topcoat layer has 2 layers. Among them, the concave-convex effect layer is printed on the cured UV wear-resistant paint layer by a flatbed inkjet printer. At this time, the concave-convex effect layer is UV transparent paint, and then according to the pattern of the pattern layer, the paint is stacked at a specific graphic position; thereby forming a concave-convex effect layer with a specific pattern.

[0005] The effect of this stacking is relatively stiff, and because the edges of the wood grain are obtuse, it is difficult to imitate the effect of real wood grain from both visual and tactile aspects. The concave and convex effect layers formed by stacking are not comfortable to the feet when used on the floor.

[0006] Second, a concave texture effect is created by brushing on the flat coating to remove the corresponding part of the texture.

[0007] The relevant prior art is introduced as follows.

[0008] CN112739463A discloses a method and apparatus for producing a surface structure, comprising the following steps: A) applying resin A to the surface of a material; B) when the resin A is in a liquid state or partially solidified, applying liquid B to at least a portion of the resin A; C) polymerizing the resin A and the liquid B separately; D) removing the polymerized liquid B to produce a three-dimensional structure.

[0009] This patent application discloses the principle of using a concave method to form a texture, and analyzes the physical and chemical properties of liquid B and resin A as embossing liquid to screen out a suitable liquid B. However, there is no special description of the performance requirements for the final product with a three-dimensional structure.

[0010] CN110773403A discloses a 3D printing plate with a brushed surface effect, the structure of which is a base layer, a UV primer layer, a UV white paint layer, a UV transition paint layer, a color pattern layer, a UV wear-resistant paint, a 3D texture layer, and a UV topcoat layer from bottom to top. A flatbed inkjet printer is used to spray varnish on the uncured UV wear-resistant paint surface, and the position of the varnish corresponds to the pattern texture position of the color pattern layer; after printing is completed, the LED provided by the printer is used for drying and curing; at this time, the cured part is limited to the part not covered by the varnish, and the wear-resistant paint of the part covered by the varnish is not cured; then a wood grain drawing machine is used to draw the uncured printed parts in the 3D texture, so as to obtain a 3D texture layer.

[0011] In this patent application, varnish is printed on the uncured wear-resistant paint, and the varnish is used to cover part of the wear-resistant paint so that it will not be cured in the subsequent curing process, so that it can be removed to form grooves. Since the uncured part of the wear-resistant paint in the area blocked by the varnish is regular, the grooves formed in this way are quite different from the real wood grain in terms of both visual effect and touch. Moreover, from the patent application Figure 1 From the looks of it, the surface of the formed board is flat, and there is no focus on the three-dimensional feel of the touch.

[0012] In summary, although the second method has a greater advantage than the first method in that the three-dimensional texture obtained is closer to the real wood grain, the second method is still in its early stages and there are still many problems to be solved. For example, the wear-resistant layer is in a semi-cured or uncured form, and the texture layer is formed by drawing on these wear-resistant layers, which destroys the wear-resistant layer structure, reduces the wear resistance of the board, and even destroys the pattern of the pattern layer; for another example, the 3D structure formed has a poor three-dimensional effect, the texture is not natural enough, and especially the clarity is poor. Summary of the invention

[0013] In order to solve the above-mentioned defects existing in forming 3D texture on the existing substrate, the present invention provides a plate having a 3D texture structure.

[0014] The plate with a 3D texture structure provided by the present invention has a better 3D texture forming effect and visual effect while ensuring the wear resistance of the plate by improving the substrate for forming the 3D texture.

[0015] The scheme adopted by the present invention is as follows:

[0016] A plate with a 3D texture structure, comprising from bottom to top at least a substrate, a pattern layer, a wear-resistant layer and a topcoat layer; the wear-resistant layer comprises a thickness adjustment layer and a texture layer located above the thickness adjustment layer, the texture layer comprises a base portion and a three-dimensional portion, the three-dimensional portion is located above the base portion, the pattern layer comprises a plurality of connected or unconnected wood grain-shaped lines, the three-dimensional portion comprises a plurality of connected or unconnected wood grain-shaped grooves, at least part of the grooves correspond to the lines in one or more of the arrangement position, length or width, and at least part of the top of the topcoat layer is lower than the upper surface of the three-dimensional portion.

[0017] At present, most 3D digital printing plates are in the theoretical research and development stage, and there are relatively few 3D digital printing plates circulating in the market. The existing plates are compared with 2D printing plates in terms of vision and touch. It is found that the clarity of 3D digital printing plates is obviously insufficient, the pattern is blurred, and the three-dimensional sense of touch is relatively weak. The inventor of the present invention analyzes these defects in order to solve them.

[0018] The 3D digital printing plate in the prior art forms a three-dimensional structure on the uncured wear-resistant layer above the pattern layer. Since the pattern layer is not protected, the pattern layer is easily damaged during the wire drawing process or in the later use process, that is, the wear resistance is poor. For example, the 3D printing plate disclosed in CN110773403A mentioned in the background technology forms a wire drawing groove on the uncured wear-resistant layer covered with varnish. Whether the wire drawing process will damage the pattern on the pattern layer depends on the depth of the 3D texture. If a deeper 3D texture is required, the depth penetrates the thickness of the wear-resistant layer, and the problem of the pattern layer being damaged mentioned above still exists.

[0019] In addition, compared with 2D printed plates, 3D printed plates need to form 3D textures. A wear-resistant layer is used on top of the pattern layer to form the 3D texture, and then multiple layers such as a topcoat layer are coated on it, which results in a decrease in the pattern clarity of the formed plate.

[0020] Therefore, how to balance wear resistance and pattern clarity is a difficult problem currently encountered by 3D digital printing sheets.

[0021] In the face of the above problems, most solutions are to improve the composition of the wear-resistant paint or topcoat, so that the wear-resistant layer and topcoat layer have good wear resistance and transparency. Another solution is to improve the 2D ink that forms the pattern layer, so that the connection between the pattern layer and the substrate layer or primer layer is enhanced.

[0022] The present invention breaks through the conventional methods in the field, overcomes the prejudice that adding a coating will reduce the clarity of a pattern, and creatively sets the wear-resistant layer as a thickness adjustment layer and a texture layer. The thickness adjustment layer is formed by pre-curing before the texture layer is coated. In the thickness adjustment layer, no groove structure is formed. The thickness adjustment layer protects the pattern layer from being damaged during the process of forming the groove. The thickness adjustment layer also provides excellent wear resistance to ensure the wear resistance of the plate to resist the friction of the plate caused by external forces during use.

[0023] The texture layer in the present invention is used as a 3D texture structure forming part, and a groove structure is formed on it to form a three-dimensional part of the texture layer. However, on the texture layer, the groove does not penetrate, and a base part is reserved below the three-dimensional part, and no groove is formed on the base part. After the wear-resistant layer is set as the thickness adjustment layer and the texture layer, there must be a problem of connection strength, and it is also found in actual use that the formed plate is easy to film and fall off on the surface after a period of use. The texture layer is provided with a base part, and there is a certain distance (the thickness of the base part) between the bottom of the groove and the thickness adjustment layer. The groove will not penetrate the thickness direction of the texture layer, ensuring the integrity of the contact surface between the thickness adjustment layer and the texture layer, which is conducive to ensuring the connection strength between the thickness adjustment layer and the texture layer. Moreover, if there is no base part, the thickness adjustment layer is very easy to be scratched in the process of forming the groove, and the scratched part will affect the visual effect and clarity of the pattern. Therefore, compared with the wear-resistant layer without a base part, the 3D texture formed by the present invention has better clarity and better visual effect.

[0024] Moreover, the inventors found that before applying the wear-resistant layer forming the 3D texture, a cured thickness adjustment layer is formed on the pattern layer, which can appropriately increase the thickness of the three-dimensional part of the texture layer without affecting the clarity of the pattern, and still have ideal clarity. Using a thicker three-dimensional part can achieve a 3D texture with deeper lines, and even after covering the topcoat layer, it still has a clear sense of concave and convex, and the touch is closer to the natural effect. For example, the texture layer usually reaches 100g / m 2 After forming a cured thickness adjustment layer on the pattern layer, the texture layer can reach 150g / m 2 And above, it still has ideal clarity.

[0025] The texture layer of the present invention has different thicknesses, and the clarity of the pattern will be affected. In this case, the clarity can be adjusted by adjusting the coating thickness of the thickness adjustment layer.

[0026] In some specific embodiments, the bottom and / or inner wall of the groove has a plurality of protrusions. The protrusions may be regular or irregular. On the one hand, the protrusions are conducive to improving the adhesion of the topcoat to improve the surface performance of the board. On the other hand, the presence of the protrusions makes the touch feel of the board more realistic.

[0027] In some specific embodiments, the number of protrusions on the bottom of at least part of the grooves exceeds the number of protrusions on the sidewalls, and / or the area of ​​the protrusions on the bottom is larger than the area of ​​the protrusions on the sidewalls.

[0028] In certain specific embodiments, the protrusions account for at least 1%, or at least 5%, or at least 10%, or at least 15%, or at least 20%, or at least 25%, or at least 30%, or at least 35%, or at least 40%, or at least 45% of the total area of ​​the inner surface of the groove, but generally not more than 50%.

[0029] In some specific embodiments, at least part of the sidewalls and bottoms of the grooves are connected at an obtuse angle. The grooves connected at an obtuse angle feel closer to the texture of real wood grain and are more comfortable to touch.

[0030] In some specific embodiments, the side wall has raised and / or recessed areas to enrich the touch feel.

[0031] In some specific embodiments, the depth of the groove is 0.03 mm to 0.20 mm, more preferably 0.08 mm to 0.20 mm.

[0032] In some specific embodiments, at least part of the groove includes a tactile deepening portion in the middle, visual simulation portions at both ends, and a transition portion between the tactile deepening portion and the visual simulation portion, and the width of at least part of the visual simulation portion is smaller than the width of the tactile deepening portion.

[0033] In some more preferred embodiments, the depth of the visual simulation portion of at least a portion of the grooves is smaller than the depth of the deepened tactile portion.

[0034] In the above technical solution, the groove is divided into three parts, and different parts have different main functions. The hand-feel deepening part provides a more obvious three-dimensional touch; the visual simulation part, in conjunction with the hand-feel deepening part, provides a touch closer to the real wood grain. The visual simulation part can also enhance the visual effect, making the board look closer to the real wood grain; the transition part mainly serves to connect the first two parts. The different control depths and widths of each part realize the 3D texture effect of the board as a whole, which is closer to the real wood texture in terms of vision and touch.

[0035] In some specific embodiments, the thickness of the thickness adjustment layer and the thickness of the texture layer may be the same or different.

[0036] In some other preferred embodiments, the thickness of the texture layer is greater than the thickness of the thickness adjustment layer. The thickness of the two parts is determined according to their functions. The texture layer is used to form a groove structure, and a larger thickness is required to form a deeper groove to achieve a more three-dimensional 3D effect.

[0037] The wear-resistant layer is formed by coating with wear-resistant paint. The composition of the wear-resistant paint usually includes photosensitive resin, photoinitiator and other additives. Other additives can be a combination of one or more of curing agent, catalyst, cross-linking agent, leveling agent, antioxidant, defoaming agent, inorganic filler, pigment, plasticizer, etc.

[0038] In some specific embodiments, the photosensitive resin is a combination of one or more of epoxy resin, acrylic resin, acrylic modified polyurethane resin, acrylic modified silicone resin, acrylic modified epoxy resin and the like.

[0039] In some specific embodiments, the material of the thickness adjustment layer and the material of the texture layer may be the same or different.

[0040] In other embodiments, the material of the thickness adjustment layer is different from the material of the texture layer. The thickness adjustment layer and the texture layer each have different main functions, and selecting materials according to their functional requirements is more conducive to the functions of different forms of different wear-resistant layers.

[0041] In some specific embodiments, the coating amount of the wear-resistant paint used in the thickness adjustment layer is 35 g / m 2 Up to 55g / m 2 .

[0042] In some specific embodiments, the coating amount of the wear-resistant paint used in the texture layer is greater than or equal to 150 g / m 2 .

[0043] In some specific embodiments, the texture layer is formed by two coatings, and the coating directions are opposite, and the coating amount of the wear-resistant paint used in the first coating is greater than or equal to 75g / m 2 The coating amount of the wear-resistant paint used in the second coating is greater than or equal to 75g / m 2 .

[0044] The texture layer often needs to be thicker to form deeper grooves to highlight the concave and convex feeling of touch. After testing, the inventor of the present invention found that only when the total amount of coating used in the texture layer is greater than 150g / m 2When the texture is more than 150g / m 2 The above method not only increases the processing difficulty, but also causes uneven roller coating, resulting in uneven internal structure and thickness of the texture layer, thus affecting the overall clarity. In this scheme, the texture layer is formed by two coatings, and the roller coating directions are opposite, so that when the second coating is implemented, a force opposite to the internal stress of the uncured second layer can be provided, thereby weakening or offsetting the original internal stress of the texture layer, thereby avoiding cracks in the middle of the cured texture layer, and overcoming the defect of poor clarity caused by internal cracks.

[0045] The substrate can be a plate material of different properties, including wood and wood derivatives, such as SPC stone plastic board, etc. The material of the substrate is selected according to the specific application.

[0046] The thickness of the substrate layer may be determined according to the specific application, for example in the case of decorative panels for furniture, it is usually between 5 mm and 25 mm, while the thickness for producing flooring is between 2 mm and 6 mm.

[0047] In some specific embodiments, the above-mentioned sheet material also includes a white film, which is formed on the substrate in any manner, such as a PVC white film, attached to the substrate to adjust the base color of the substrate to highlight the clarity of the pattern printed in the subsequent pattern layer.

[0048] In some specific embodiments, the above-mentioned board further includes a primer layer, which is coated on the white film to provide good adhesion for subsequent coatings.

[0049] In some specific embodiments, the above-mentioned board further includes a color paint layer located between the primer layer and the pattern layer.

[0050] In some specific embodiments, the color paint layer is formed by rolling or spraying the color paint on the solidified primer and then solidifying it. The color of the color paint is determined according to the requirements of the printed pattern, and is generally white. Other colors can also be selected according to the requirements of the printed pattern. This layer can correct the base color of the substrate on the one hand, and on the other hand, it can also adjust the polarity of the substrate surface to be printed, thereby improving the adhesion of the pattern layer.

[0051] The primer layer, pattern layer, color paint layer, and wear-resistant layer can be cured by light curing, heat curing, or electron beam curing, and light curing can be performed by, for example, UV lamp, mercury lamp, LED lamp, potassium lamp, etc. In particular, LED lamp is used for curing, which has little light pollution.

[0052] In some specific embodiments, the pattern layer is formed by printing a pattern on the primer layer using a multi-color ink digital printer and then photocuring it. Various patterns such as wood grain, stone grain or personalized customized patterns can be printed.

[0053] The curing of the pattern layer can be light curing, heat curing or electron beam curing, and light curing can be performed by, for example, UV lamp, mercury lamp, LED lamp, potassium lamp, etc. In particular, LED lamp is used for curing, which has little light pollution.

[0054] In some specific embodiments, the pattern layer and the texture layer are formed by digital printing, and the digital printing ink can be UV ink, weak solvent ink, water-based ink or oil-based ink.

[0055] The topcoat layer is formed by coating the topcoat on the wear-resistant layer and then curing it.

[0056] The topcoat layer can be one or more layers, mainly giving the board a bright and matte effect, improving the glossiness of the board surface. The topcoat layer can also give the board some other functions, such as anti-fouling, anti-mildew, anti-bacteria, waterproof, fireproof, anti-crack, anti-slip, negative ion, formaldehyde removal, and wear resistance.

[0057] The present invention also provides a method for preparing the above-mentioned plate with a 3D texture structure, comprising the following steps:

[0058] S1. Applying a paint on a substrate and curing the paint to form a paint layer;

[0059] S2. Printing a wood grain pattern on the paint layer to form a pattern layer;

[0060] S3. Applying a wear-resistant paint on the pattern layer and curing it to form a wear-resistant layer with a thickness adjustment layer;

[0061] S4. Applying a wear-resistant paint on the wear-resistant layer to adjust the thickness of the wear-resistant layer without curing to form a texture layer;

[0062] S6. Applying embossing liquid to the surface of at least a portion of the texture layer;

[0063] S7. Curing the texture layer and removing the uncured or incompletely cured portion, thereby forming a groove on the texture layer;

[0064] S8. Apply a topcoat on the surface obtained in S7, and cure it to form a topcoat layer, thereby obtaining a plate with a 3D texture structure.

[0065] In the above preparation method, the creative steps are steps S3 and S7.

[0066] When forming the wear-resistant layer, S3 of the present invention first coats and solidifies to form a thickness adjustment layer, that is, before coating the texture layer, the thickness adjustment layer is solidified through a curing process.

[0067] The plate formed by this method has at least the following advantages:

[0068] Protective pattern layer: The thickness adjustment layer has been solidified before the groove is formed, and the thickness adjustment layer does not form a groove structure. The thickness adjustment layer protects the pattern layer from being damaged during the process of forming the groove.

[0069] It has better wear resistance: the thickness adjustment layer is a complete layer, which can provide excellent wear resistance and ensure the wear resistance of the plate to resist the friction of the external force on the plate during use.

[0070] Providing higher clarity: This is also an unexpected effect of the plate made by this method. After adding an extra layer (thickness adjustment layer), the 3D texture formed by the present invention has better clarity and better visual effect than the wear-resistant layer without a thickness adjustment layer. The reason for this may be: In the prior art, the texture layer is directly coated on the pattern layer to form a texture layer. During the curing process of the texture layer, the energy used for curing the wear-resistant paint is usually input from the top of the texture layer. The wear-resistant paint on the top will be cured first, and the wear-resistant paint on the bottom will be cured later. Since the wear-resistant paint is often accompanied by a certain volume shrinkage during the curing process, a certain internal stress will be generated. These internal stresses will be superimposed downward, thereby reaching a maximum value at the bottom of the resin liquid. If the wear-resistant paint is in direct contact with the pattern layer at this time, once the maximum internal stress is greater than the bonding force between the pattern layer and the next layer, it will cause slippage between the pattern layer and the surface of the plate, which will cause the pattern layer at the bottom to be difficult to correspond to the groove, resulting in visual blur and a significant reduction in clarity. In the present invention, a thickness adjustment layer with a smaller thickness is first formed on the pattern layer. The internal stress generated by the thickness adjustment layer after solidification is relatively weak, and will not exert excessive force on the pattern layer, thereby ensuring the accuracy of the wood grain position of the pattern layer. On the other hand, in the prior art, the texture layer is directly coated on the pattern layer. Since the wood grain pattern on the pattern layer is discontinuous, the wear-resistant paint is coated on the discontinuous wood grain pattern. Due to the influence of the wood grain pattern, the consistency of the shrinkage of the wear-resistant paint during solidification is affected, resulting in uneven internal shrinkage of the texture layer after solidification, and the appearance of fine lines, thereby causing a decrease in clarity. The surface of the thickness texture layer of the present invention is smooth, and the wear-resistant paint of the texture layer has consistent shrinkage when solidified on the surface, and no fine lines will appear inside the texture layer, resulting in good clarity.

[0071] Another function of the thickness adjustment layer is that the clarity of the plate can be improved by adjusting its thickness. The texture layer is used as a part of the 3D texture structure, and the groove structure formed on it will not affect the wear resistance of the plate. Moreover, compared with the wear-resistant layer without the thickness adjustment layer, the 3D texture formed by the present invention has better clarity and better visual effect.

[0072] Achieve a deeper 3D texture: This method can also appropriately increase the thickness of the texture layer without affecting the clarity of the pattern, and still have ideal clarity. Using a thicker texture layer can achieve a deeper 3D texture, even after covering the topcoat layer, it has a clear sense of concave and convex, and the touch is closer to the natural effect.

[0073] In the S7 of the present invention, when forming the groove of the texture layer, a base portion is reserved. The formation of the base portion is based on the difference between the thickness of the texture layer and the depth of the groove. The reserved base portion has at least the following advantages:

[0074] Enhance the connection between the texture layer and the thickness adjustment layer: the texture layer is provided with a base part, and there is a certain distance (the thickness of the base part) between the bottom of the groove and the thickness adjustment layer. The groove will not penetrate the thickness direction of the texture layer, thereby ensuring the integrity of the contact surface between the thickness adjustment layer and the texture layer, which is beneficial to ensuring the connection strength between the thickness adjustment layer and the texture layer.

[0075] Improve clarity: If there is no base part, the thickness adjustment layer is very easy to be scratched during the process of forming the groove, and the scratched part will affect the visual effect and clarity of the pattern. Therefore, compared with the wear-resistant layer without a base part, the 3D texture formed by the present invention has better clarity and better visual effect.

[0076] The texture layer formed by the above method has a groove on the upper part, which is a three-dimensional part, and a base part is reserved below the three-dimensional part, and no groove is formed on the base part. The three-dimensional part is connected with the base part as a whole and belongs to different parts of the texture layer.

[0077] In some specific embodiments, the coating amount of the wear-resistant paint used in the thickness adjustment layer is 35 g / m 2 Up to 55g / m 2 .

[0078] In some specific embodiments, the coating amount of the wear-resistant paint used in the texture layer is greater than or equal to 150 g / m 2 .

[0079] In some specific embodiments, the base part and the three-dimensional part of the texture layer are formed by two coatings, and the coating amount of the wear-resistant paint used in the base part is greater than or equal to 75g / m 2 The coating amount of the wear-resistant paint used in the three-dimensional part is greater than or equal to 75g / m 2 .

[0080] In certain specific embodiments, the coating direction for forming the base portion is opposite to the coating direction for forming the three-dimensional portion.

[0081] In some specific embodiments, in step S5, a steel brush is used to remove the uncured or incompletely cured portion. Using a steel brush to remove the uncured portion can easily form a finer brushed texture, and the formed groove has a shape closer to the natural wood texture.

[0082] The present invention adopts a specific preparation method to form a specific plate with a 3D texture structure. The pattern presented by the plate has excellent clarity, and the presented 3D texture has a more excellent three-dimensional sense and touch feel.

[0083] The present invention also provides applications of the above-mentioned board or the board obtained by the above-mentioned preparation method, specifically applications in floors, wall panels or ceiling panels.

[0084] In summary, the present invention has the following advantages:

[0085] 1. The present invention sets the wear-resistant layer as a thickness adjustment layer and a texture layer. No groove structure is formed in the thickness adjustment layer. The thickness adjustment layer protects the pattern layer from being damaged during the formation of the groove. The thickness adjustment layer also provides excellent wear resistance to ensure the wear resistance of the plate to resist the friction of the plate caused by external forces during use. The texture layer is a part forming the 3D texture structure. Forming the groove structure on it will not affect the wear resistance of the plate. Moreover, compared with the wear-resistant layer without the thickness adjustment layer, the 3D texture formed by the present invention has better clarity and better visual effect.

[0086] 2. The thickness adjustment layer in the present invention can also be used to adjust the clarity of the board. The clarity of the board can be adjusted by changing the thickness of the thickness adjustment layer according to the thickness of the texture layer and the depth of the groove.

[0087] 3. The present invention uses a wear-resistant layer with a thickness adjustment layer, which can appropriately increase the thickness of the texture layer without affecting the clarity of the pattern, and still have ideal clarity. Using a thicker texture layer can achieve a 3D texture with deeper lines, and even after covering the topcoat layer, it still has a clear sense of concave and convex, and the touch is closer to the natural effect.

[0088] 4. The present invention can also use the grooves to increase the connection force between layers and ensure the overall performance of the board. BRIEF DESCRIPTION OF THE DRAWINGS

[0089] Figure 1 A schematic diagram of the hierarchical structure of a plate material provided in Example 1 of this specification;

[0090] Figure 2 A schematic diagram of a partial three-dimensional structure of a plate provided in Example 1 of this specification;

[0091] Figure 3 This is an enlarged schematic diagram of a groove of a plate provided in Example 1 of this specification;

[0092] Figure 4 A schematic diagram of a partial three-dimensional structure of a plate provided in Comparative Example 1 of this specification;

[0093] Figure 5 A top view of a plate provided for comparative example 1 of this specification;

[0094] FIG. 6 is an enlarged schematic diagram of a portion of the grooves of the plate provided in Comparative Example 4 of this specification. DETAILED DESCRIPTION

[0095] The technical solution of the present invention will be described in detail below in conjunction with specific embodiments.

[0096] Example 1

[0097] A plate with a 3D texture structure, such as the attached Figure 1 As shown, from bottom to top, it includes: a substrate 01, a white film 02, a primer layer 03, a color paint layer 04, a pattern layer 05, a wear-resistant layer 06 and a topcoat layer 07.

[0098] In this embodiment, SPC stone plastic wood is used as the substrate with a thickness of 4 mm. The white film is a commercially available PVC white film, which is attached to the substrate online after the substrate is extruded.

[0099] The primer layer is formed by using a transparent acrylic varnish, which is roller-coated on the white film and cured by UV lamp.

[0100] The color paint is white paint, which is applied by roller on the primer layer and cured by ultraviolet lamp.

[0101] The pattern layer is formed by printing a pattern with a multi-color ink digital printer and then curing it with light. In this embodiment, a wood grain pattern is printed. The pattern layer has a plurality of connected or unconnected wood grain-shaped lines.

[0102] The wear-resistant layer includes two layers, a thickness adjustment layer located above the pattern layer and a texture layer located above the thickness adjustment layer. The thickness adjustment layer is formed by coating a transparent wear-resistant paint on the pattern layer and curing it with light. Before coating the texture layer, the curing step has been completed.

[0103] The texture layer of the wear-resistant layer is formed by coating a transparent wear-resistant paint on the thickness adjusting layer. A plurality of connected or unconnected wood grain-shaped grooves 06a are provided in the texture layer. Different grooves may have different widths, depths and lengths. The width, depth and length of the grooves are related to the pattern of the pattern layer. The grooves correspond to the lines of the pattern layer in terms of arrangement position, length or width, and the pattern is accurate.

[0104] The texture layer is formed by coating the thickness adjustment layer with a wear-resistant paint, and a groove is formed on the texture layer. The maximum depth of the groove is less than the thickness of the texture layer, the bottom of the texture layer that is not penetrated is the base part, and the three-dimensional part with the groove is above the base part.

[0105] The topcoat layer is coated on the surface of the three-dimensional part of the wear-resistant layer with a top of the topcoat layer corresponding to the groove being lower than the upper surface of the three-dimensional part of other parts outside the groove.

[0106] The plate of this embodiment was analyzed by laser profilometer analysis, and the results are shown in Figure 2 and Figure 3 .

[0107] from Figure 2 It can be clearly seen that the surface of the plate provided in this embodiment has an obvious concave-convex structure brought by the grooves, and has an obvious concave-convex feeling when touched.

[0108] from Figure 3 It can be seen that a portion of the grooves have raised areas and recessed areas on the side walls of the grooves. There are irregular protrusions 06b on both the bottom and side walls of the grooves. The number of protrusions at the bottom of the groove is significantly greater than the number of protrusions on the side walls. The area of ​​the protrusions accounts for about 10% of the total area of ​​the inner surface of the groove. The number of protrusions can at least be adjusted by the diameter and distribution density of the wire brush on the steel roller of the wire drawing machine. For example, by reducing the diameter of the wire brush and increasing the density, the number of protrusions and the area ratio will decrease.

[0109] From the perspective of the structure of a single groove, a portion of the grooves as a whole includes three parts: a touch deepening area in the middle area, visual simulation parts at both ends, and a transition part between the touch deepening part and the visual simulation part. The touch deepening part is the area with the greatest depth, and some grooves can reach 0.2mm. For some grooves, the width of the visual simulation part at both ends is smaller than the width of the touch deepening part. For some grooves, the width of the visual simulation part at one end is smaller than the width of the touch deepening part, and the width of the visual simulation part at the other end is equivalent to the width of the touch deepening part. The wood texture formed by the grooves with this special structure is closer to the real wood grain in terms of visual effect and touch feel.

[0110] Example 2

[0111] This embodiment specifically describes the method for preparing a plate having a 3D texture structure according to Embodiment 1, which specifically includes the following steps:

[0112] (S.1) Place an SPC sheet with a white film and a length, width and thickness of 1260mm*970mm*4.85mm on the surface of a conveying device moving in a fixed direction;

[0113] (S.2) During the transportation process, the SPC sheet first passes through the first roller coater, the coating roller surface of which is adhered with a photocurable primer (the primer contains: 90% photocurable varnish HYS01-1, 5% photoinitiator 184, 0.5% photoinitiator TPO, 4.5% diluent hydroxyethyl acrylate). During the contact between the SPC sheet and the coating roller, 12g / m 2 The primer is applied to the surface of the SPC sheet using 395nm and 8W / cm 2 The primer is cured by a UV lamp to form a primer layer;

[0114] (S.3) The SPC sheet obtained in the previous step is passed through a second roller coater, the coating roller surface of which is adhered with a photocurable white paint (the white paint contains: 50% photocurable epoxy HYS01-1, 30% titanium dioxide, 5% photoinitiator 184, 0.5% photoinitiator TPO, 14.5% diluent hydroxyethyl acrylate). During the contact between the SPC sheet and the coating roller, 18g / m 2 The white paint is applied on the surface of the primer, and the 2 After curing with UV lamp, a white paint layer is obtained;

[0115] (S.4) The SPC sheet obtained in the previous step is conveyed to the first inkjet printer, so that the surface of the color paint layer is sprayed with 6-8 g / m 2 The ink is cured to form a pattern layer having a wood grain pattern on the surface of the primer layer;

[0116] (S.5) The SPC sheet obtained in the previous step is conveyed to the third roller coater, and 45g / m2 of the SPC sheet is roller coated on the surface of the pattern layer. 2 The photocurable resin liquid (resin liquid contains: 90% Dow Corning 65 Additive, 5% photoinitiator 184, 0.5% photoinitiator TPO, 4.5% diluent hydroxyethyl acrylate) was sequentially subjected to 395nm and 8W / cm 2 UV lamp and 160w / cm 2 After being irradiated and cured by a Hg lamp, a thickness adjustment layer is formed;

[0117] (S.6) The SPC sheet obtained in the previous step is conveyed to the fourth roller coater, so that the coating roller of the fourth roller coater is rolled along the conveying direction of the SPC sheet (the roller rotates clockwise) to coat 80g / m 2 The resin liquid (the resin liquid contains: 90% Dow Corning 65 Additive, 5% photoinitiator 184, 0.5% photoinitiator TPO, 4.5% diluent hydroxyethyl acrylate) forms the base part of the texture layer;

[0118] (S.7) After applying the first layer of resin liquid, the SPC sheet is conveyed forward along the surface of the conveying equipment, and it is ensured that the fourth roller coater does not apply any force to the resin liquid before conveying to the next roller coater;

[0119] (S.8) The SPC sheet obtained in the previous step is conveyed to the fifth roller coater, and the coating roller of the fifth roller coater is made to continue to roll-coat 75g / m against the conveying direction of the SPC sheet (the roller itself rotates in a clockwise direction). 2 The resin liquid (the resin liquid here is the same as the resin liquid in step (S.6)) forms a three-dimensional part of the texture layer;

[0120] (S.9) The SPC sheet obtained in the previous step is transported to the second inkjet printer so that 8 g / m 2 The embossing liquid (the embossing liquid comprises: 45.5% diacrylate monomer PEG600DA, 20.5% p-hydroxyanisole HQMME, 10% 2-tert-butylhydroquinone MTBHQ, 24% diethylene glycol butyl ether), and the embossing liquid is allowed to penetrate downward into the resin liquid and mix with the resin liquid;

[0121] (S.10) The SPC sheet obtained in the previous step was subjected to 395nm and 8W / cm 2 UV lamp and 160w / cm 2 Hg lamp irradiation for deep curing;

[0122] (S.11) The SPC sheet obtained in the previous step is conveyed to a cleaning device including a steel brush (steel wire diameter 0.02 mm), so that the mixed part of the embossing liquid and the resin liquid is brushed out by the steel brush, thereby forming grooves at these parts;

[0123] (S.12) The SPC sheet obtained in the previous step is coated with 12g / m 2 The topcoat is at 395nm and 8W / cm 2 The UV lamp is used to cure the paint to obtain the topcoat layer.

[0124] Comparative Example 1

[0125] The steps are basically the same as those in Example 2, except that step (S.5) is omitted in Comparative Example 1, so the prepared plate does not contain a thickness adjustment layer. Figure 4 and Figure 5 They are respectively a three-dimensional structural schematic diagram and a top structural schematic diagram of the board prepared in Comparative Example 1 of the present disclosure. It can be seen from the figure that after omitting step (S.5), the average depth of the wood grain formed is smaller, and the texture of the board surface is quite different from the real wood grain in terms of vision and touch.

[0126] Comparative Example 2

[0127] The steps are basically the same as those in Example 2, except that in step (S.5) of this comparative example, after the wear-resistant paint is rolled, no curing treatment is performed. The board obtained in this comparative example has a similar wood grain depth to the board obtained in Example 2, but its clarity and wear resistance are significantly worse.

[0128] Comparative Example 3

[0129] The steps are basically the same as those in Example 2, except that after step (S.8), the wear-resistant paint is irradiated with ultraviolet light, so that an incompletely cured texture layer is obtained. The average depth of the wood grain formed is lower and the clarity is reduced.

[0130] Comparative Example 4

[0131] The steps are basically the same as those in Example 2, except that the amount of embossing liquid applied in step (S.9) is 15 g / m 2 The maximum depth of the grooves formed is slightly greater than the thickness of the texture layer. At the deepest point, the texture layer is penetrated. The clarity of the plate formed by this decreases.

[0132] Example 3

[0133] The steps are basically the same as those in Example 2, except that (S.6) to (S.8) of this embodiment are combined into one step (S.6), as follows:

[0134] (S.6) The SPC sheet obtained in the previous step is conveyed to the fourth roller coater, so that the coating roller of the fourth roller coater rolls 155g / m on the surface of the thickness adjustment layer along the conveying direction of the SPC sheet. 2 The resin liquid (the resin liquid contains: 90% DowCorning 65 Additive, 5% photoinitiator 184, 0.5% photoinitiator TPO, 4.5% diluent hydroxyethyl acrylate) is used to form a texture layer.

[0135] Example 4

[0136] The steps are basically the same as those in Example 2, except that (S.8) the roller coating directions of the two coatings are the same. (S.6) to (S.8) of this embodiment are as follows:

[0137] (S.6) The SPC sheet obtained in the previous step is conveyed to the fourth roller coater, so that the coating roller of the fourth roller coater is rolled along the conveying direction of the SPC sheet (the roller rotates clockwise) to coat 80g / m 2The resin liquid (the resin liquid contains: 90% Dow Corning 65 Additive, 5% photoinitiator 184, 0.5% photoinitiator TPO, 4.5% diluent hydroxyethyl acrylate) forms the base part of the texture layer;

[0138] (S.7) After applying the first layer of resin liquid, the SPC sheet is conveyed forward along the surface of the conveying equipment, and it is ensured that the fourth roller coater does not apply any force to the resin liquid before conveying to the next roller coater;

[0139] (S.8) The SPC sheet obtained in the previous step is conveyed to the fifth roller coater, and the coating roller of the fifth roller coater continues to roll-coat 75g / m along the conveying direction of the SPC sheet (the roller itself rotates in a clockwise direction). 2 The resin liquid (the resin liquid here is the same as the resin liquid in step (S.6)) forms the three-dimensional part of the texture layer.

[0140] Product testing:

[0141] Surface wear resistance test: Tested in accordance with standard GT / T 18102-2020.

[0142] Surface scratch resistance index test: Tested in accordance with standard GT / T 18102-2020.

[0143] Clarity test: Tested in accordance with standard JIS K7374.

[0144] Touch depth level test.

[0145] Test the proximity between touch feel and real wood grain.

[0146] Touch depth level test method and standard:

[0147] Organize 15 assessors to conduct touch depth evaluation on the panels to be tested. They touch the surface of the panels with their hands to feel the concave and convex feel of the surface and the depth of the grooves of the panels, and record the evaluation results according to grades. The grade with the largest number of people is the final evaluation grade of the panels.

[0148] The touch depth is divided into five levels. The five levels and evaluation criteria are shown in Table 1.

[0149]

[0150] Note: From level one to level five, the sense of concavity and convexity gradually decreases, and the grooves gradually become shallower.

[0151] Test method and standard for proximity between touch feeling and real wood grain:

[0152] Organize 15 assessors to test the proximity between touch feel and real wood grain. First, touch the wood grain of a real piece of wood, then touch the surface of the board to be tested, evaluate the degree of proximity, and record the evaluation results according to grades. The grade with the largest number of people is the final evaluation grade of the board.

[0153] The closeness of touch feel to real wood grain is divided into four levels. The five levels and evaluation criteria are shown in Table 2.

[0154]

[0155] The test results of the surface wear resistance, scratch resistance and clarity performance of the plates of Examples 2-4 and Comparative Examples 1-4 are shown in Table 3 below:

[0156]

[0157] Result analysis: Compared with Example 2, Comparative Example 1 does not set a thickness adjustment layer. The wear resistance of the obtained plate is greatly reduced, and the pattern layer is partially damaged, and the clarity is significantly reduced.

[0158] Compared with Example 2, in Comparative Example 2, the thickness adjustment layer was not cured but the texture layer was directly coated, and the clarity of the formed plate structure was significantly reduced.

[0159] In Comparative Example 3 compared to Example 2, the texture layer is not completely cured before the embossing liquid is applied. In this case, it is not conducive to the penetration of the embossing liquid, resulting in a lower depth of the final wood grain, making the three-dimensional effect of the texture poor. Moreover, due to the poor penetration effect of the embossing liquid, the matching degree between the formed grooves and the wood grain pattern of the pattern layer is reduced, resulting in a decrease in clarity.

[0160] Compared with Example 2, Comparative Example 4 does not reserve the base portion of the texture layer. Under this structure, the clarity of the board will be affected to a certain extent.

[0161] Compared with Example 2, Example 3 forms the texture layer by a one-time coating method. During the coating process, the wear-resistant paint inside the texture layer is uneven, which has a certain impact on the clarity.

[0162] Compared with Example 2, Example 4 adopts the coating method of twice in the same direction to form the texture layer. Compared with the coating method in the opposite direction, the clarity is also affected.

[0163] The touch depth level and touch feel of the boards of Examples 2-4 and Comparative Examples 1-4 were tested for proximity to real wood grain. The test results are shown in Table 4 below:

[0164]

[0165] Embodiment 5:

[0166] The difference from Example 2 is that in step (S.11), a steel brush with a thicker wire diameter (about 0.05 mm in diameter) is used to brush off the mixed part of the embossing liquid and the resin liquid, thereby forming grooves with more protrusions on the surface at these locations; statistics show that the protrusions account for about 30% of the total inner surface area of ​​the grooves.

[0167] Comparative Example 5:

[0168] The difference from Example 2 is that in step (S.11), a fine brush (the diameter of the hair is about 0.01 mm) is used to brush away the mixed part of the embossing liquid and the resin liquid, so as to form surface grooves at these parts. The grooves formed in this way have basically no obvious protrusions on the surface. The laser profilometer analysis shows that Figure 6 .

[0169] The relevant performance tests were performed on the plates of Example 5 and Comparative Example 5, and the performance test results are shown in Table 5 below:

[0170]

[0171] It can be seen from Table 5 that the clarity of the board of comparative example 5 is worse than that of the board of example 5, and further by touching the surfaces of the boards of example 5 and comparative example 5, the touch feel of example 5 is closer to the real wood grain, and visually it is also closer to the real wood grain.

Claims

1. A plate with a 3D texture structure, comprising at least a substrate, a pattern layer, a wear-resistant layer and a topcoat layer from bottom to top; characterized in that: The wear-resistant layer includes a thickness adjustment layer and a texture layer located above the thickness adjustment layer, the texture layer includes a base part and a three-dimensional part, and the three-dimensional part is located above the base part; the pattern layer includes a plurality of connected or unconnected wood grain-shaped lines, and the three-dimensional part includes a plurality of connected or unconnected wood grain-shaped grooves, at least part of the grooves correspond to the lines in one or more of the arrangement position, length or width, and the top of at least part of the topcoat layer is lower than the upper surface of the three-dimensional part; the texture layer is formed by coating twice, and the roller coating directions are opposite.

2. The plate with a 3D texture structure according to claim 1, characterized in that: The bottom and / or side wall of the groove has a plurality of protrusions.

3. The plate with a 3D texture structure according to claim 1, characterized in that: The number of protrusions on the bottom of at least part of the grooves exceeds the number of protrusions on the side walls, and / or the area of ​​the protrusions on the bottom is larger than the area of ​​the protrusions on the side walls.

4. The plate with a 3D texture structure according to claim 2, characterized in that: The protrusions occupy at least 1% of the total area of ​​the inner surface of the recess.

5. The plate with a 3D texture structure according to claim 2, characterized in that: At least part of the sidewalls and the bottom of the groove are connected at an obtuse angle.

6. The plate with a 3D texture structure according to claim 2, characterized in that: The side walls have raised and / or recessed areas.

7. The plate with a 3D texture structure according to claim 1, characterized in that: The three-dimensional part is integrally connected with the base part.

8. The plate with a 3D texture structure according to claim 1, characterized in that: The maximum depth of the groove is less than the thickness of the texture layer.

9. The plate with a 3D texture structure according to claim 1, characterized in that: The thickness of the three-dimensional part is greater than the thickness of the base part.

10. The plate with a 3D texture structure according to claim 1, characterized in that: The depth of the groove is 0.03 mm to 0.20 mm.

11. The plate with a 3D texture structure according to claim 1, characterized in that: At least part of the groove includes a deepened tactile portion in the middle, visual simulation portions at both ends, and a transition portion between the deepened tactile portion and the visual simulation portion, and at least part of the visual simulation portion has a width smaller than that of the deepened tactile portion.

12. The plate with a 3D texture structure according to claim 11, characterized in that: The depth of the visual simulation portion of at least part of the groove is smaller than the depth of the deepened hand feel portion.

13. The plate with a 3D texture structure according to claim 1 or 2, characterized in that: The coating amount of the wear-resistant paint used in the thickness adjustment layer is 35 g / m 2 Up to 55g / m 2 .

14. The plate with a 3D texture structure according to claim 1, characterized in that: The coating amount of the wear-resistant paint used in the texture layer is greater than or equal to 150g / m 2 .

15. The plate with a 3D texture structure according to claim 14, characterized in that: The coating amount of the wear-resistant paint used on the base part is greater than or equal to 75g / m 2 The coating amount of the wear-resistant paint used in the three-dimensional part is greater than or equal to 75g / m 2 .

16. The plate material with a 3D texture structure according to claim 1, characterized in that: The board also includes a color paint layer located between the substrate and the pattern layer.

17. The plate with a 3D texture structure according to claim 16, characterized in that: The board also includes a primer layer located between the substrate and the color paint layer.

18. The plate with a 3D texture structure according to claim 17, characterized in that: The board also includes a white film located between the substrate and the primer layer.

19. The plate with a 3D texture structure according to claim 16, characterized in that: The color paint layer is white.

20. The plate with a 3D texture structure according to claim 1, characterized in that: The topcoat layer comprises two or more layers.

21. Use of the board material as claimed in any one of claims 1 to 20 in floor panels, wall panels or ceiling panels.

Images