A stain-resistant, deformation-resistant, skin-feel molded door panel and its manufacturing process

Abstract

This invention discloses a stain-resistant, deformation-resistant, skin-feel molded door panel and its manufacturing process. The stain-resistant, deformation-resistant, skin-feel molded door panel includes, from top to bottom, a first decorative layer, a stabilizing layer, a first balancing layer, a substrate layer, a second balancing layer, a second decorative layer, and a stain-resistant layer. The substrate layer is medium-density fiberboard (MDF), the first decorative layer is melamine-impregnated paper, the stabilizing layer is meltblown nonwoven fabric, the first and second balancing layers are resin films, and the second decorative layer is a skin-feel film. The first decorative layer, stabilizing layer, first balancing layer, and substrate layer are laminated on one side and then hot-pressed together; the skin-feel film and second balancing layer are hot-pressed together with the substrate layer on the other side. This stain-resistant, deformation-resistant, skin-feel molded door panel manufacturing process is simple, the processed door panel has good bonding performance, the product structure is stable, the surface physical and chemical properties are excellent, and it is effectively stain-resistant and easy to clean.

Description

Technical fields:

[0001] This invention relates to the field of furniture panel technology, specifically to a stain-resistant, deformation-resistant, skin-feel molded door panel and its manufacturing process. Background technology:

[0002] Skin-feel molded door panels are popular in the wardrobe and cabinet market due to their diverse styles and one-piece edge molding. However, due to the processing requirements of the shaped milling and the different tension of the surface materials on both sides, the door panels are prone to deformation and have poor stain resistance.

[0003] To address the deformation issue, many manufacturers have replaced the melamine-impregnated paper backing layer with a 0.1-0.12mm thick PVC film to improve stress balance with the front surface coating. However, this undoubtedly increases production costs and process complexity. Furthermore, the thinner PVC film results in poorer texture and pattern decoration, reducing the product's aesthetic appeal. Therefore, further improvements are needed. Summary of the Invention:

[0004] The technical problem to be solved by the present invention is to provide a stain-resistant and deformation-resistant skin-feel molded door panel and its manufacturing process, so as to solve the problem that the existing skin-feel molded door panels on the market are prone to moisture deformation and surface stains during use, which are difficult to wipe and clean. The stain-resistant and deformation-resistant skin-feel molded door panel has good bonding performance, stable product structure, excellent surface physical and chemical properties, effective stain resistance, easy to clean, and convenient processing.

[0005] The technical solution of this invention is to provide a stain-resistant, deformation-resistant, skin-feel molded door panel, comprising, from top to bottom, a first decorative layer, a stabilizing layer, a first balancing layer, a substrate layer, a second balancing layer, a second decorative layer, and a stain-resistant layer, wherein the substrate layer is medium-density fiberboard, the first decorative layer is melamine-impregnated paper, the stabilizing layer is meltblown nonwoven fabric, the first balancing layer and the second balancing layer are resin films, and the second decorative layer is a skin-feel film. The first decorative layer, the stabilizing layer, the first balancing layer, and the substrate layer are laminated on one side and then hot-pressed together, and the skin-feel film and the second balancing layer are hot-pressed together with the substrate layer on the other side.

[0006] This invention uses a balancing layer of polyethylene film instead of the original liquid adhesive, saving the manual labor of applying adhesive and the time spent waiting for drying, simplifying the processing. Simultaneously, the polyethylene film, due to its excellent thermoplasticity, can bond well with the substrate surface, forming a good covering effect on medium-density fiberboard, preventing moisture movement, reducing the risk of moisture absorption and deformation, resulting in good bonding performance and stable product structure. Furthermore, adding a stabilizing layer of meltblown nonwoven fabric under the first decorative layer can better improve the toughness and tensile strength of the impregnated paper, preventing cracking and deformation on the back due to excessive tension of the skin-feel film on the front of the molded door panel, and better resisting the stress difference caused by the different materials on the front and back. Moreover, this back structure reduces production costs and process complexity compared to using a thin PVC film for vacuum forming on the back. The stain-resistant coating can be applied after the molded door panel is formed, avoiding the surface treatment during the skin-feel film production process, which increases hardness and brittleness, making it impossible to bend and shape. After coating and drying, the surface film has a good effect, effectively preventing stains and improving stain resistance.

[0007] Preferably, the stain-resistant layer is formed by coating with a polymer resin, wherein the polymer resin, by weight, comprises 30-50 parts of waterborne polyurethane, 30-60 parts of acrylic resin, 2-8 parts of the fluorine modifier dodecafluoroheptyl methacrylate, 3-5 parts of perfluorooctylhexanediol, 2-5 parts of the silicone modifier hydroxyl silicone oil, and 3-10 parts of butanediol ester.

[0008] Preferably, the meltblown nonwoven fabric has a thickness of 0.15-0.25 mm and a basis weight of 80-180 g / m². 2 .

[0009] Preferably, the resin film is a polyethylene film with a thickness of 0.08-0.12 mm and a density of 0.8-0.9 g / cm³. 3 .

[0010] Preferably, the waterborne polyurethane emulsion should meet the following specifications: solid content 37±1%, pH value (25℃) 6.0-7.0, viscosity 250-400mPa·s, elongation at break 1400%, and tensile strength 1.3MPa.

[0011] Furthermore, the medium-density fiberboard is a pre-treated medium-density fiberboard that has undergone milling and grinding.

[0012] Furthermore, the skin-feel film is a thermoformed PVC film.

[0013] In addition, the present invention also provides a manufacturing process for the above-mentioned stain-resistant, deformation-resistant, skin-feel molded door panel, including the following steps:

[0014] Step 1: Select meltblown nonwoven fabric and polyethylene film of specific thickness and weight. Place melamine-impregnated paper as the first decorative layer, meltblown nonwoven fabric as the stabilizing layer, and polyethylene film as the balancing layer on the surface of medium-density fiberboard (which has been milled and polished) as the substrate layer in sequence. Then, use a single-layer hot press to bond the three together. The hot pressing temperature is 120-140℃, the time is 2-3 minutes, and the unit pressure is 0.8-1.0MPa.

[0015] Step 2: Cut the polyethylene film as the balancing layer and the skin-feel film as the second decorative layer to the same size and place them into a vacuum forming machine. Heat the polyethylene film and the skin-feel film and pressurize the equipment cavity. The temperature is set between 130-160℃ and adjusted according to the softening temperature of different skin-feel films. Then, compressed air is injected to pressurize and soften the film so that the skin-feel film covers the board.

[0016] Step 3: After the skin-feel film, serving as the second decorative layer, is molded and stabilized on the sample surface, the functional resin, serving as the stain-resistant layer, is applied to the molded door panel surface. Due to the diverse shapes of the panels, roller coating cannot achieve sufficient coverage; therefore, a brush coating method is used, with the coating amount controlled at 15-25 g / m². 2 After coating, use low-temperature drying at 70-85℃ for 30-60 minutes; after drying, allow to cure for 2-5 days to obtain a stain-resistant, deformation-resistant, skin-feel molded door panel.

[0017] As a preferred option, the following steps are included:

[0018] Step 1, select a weight of 120g / m 2 Meltblown nonwoven fabric with a thickness of 0.12mm and a thickness of 0.08mm with a density of 0.8g / cm³. 3 The polyethylene film is made by placing melamine-impregnated paper, meltblown nonwoven fabric and polyethylene film in sequence on the surface of medium density fiberboard that has been milled and polished, and then bonding the three together by a single-layer hot press at a temperature of 130°C for 2 minutes and a unit pressure of 0.8MPa.

[0019] Step 2, with a thickness of 0.08mm and a density of 0.8g / cm³. 3 After the polyethylene film and the 0.35mm thick skin-feel film are cut to the same size, they are placed into a vacuum forming machine. The polyethylene film and the skin-feel film are heated and the equipment cavity is pressurized. The temperature is set between 150℃, the positive pressure is set to 4.0 bar and the negative pressure to -0.7 bar. After a preheating time of 40 seconds, a vacuum treatment is performed for 8 seconds, followed by a pressurization treatment for 20 seconds, so that the PVC film is wrapped on the board.

[0020] Step 3: After the skin-feel film has stabilized on the sample surface, the functional resin is coated onto the molded door panel surface. Due to the diverse shapes of the panels, roller coating cannot achieve sufficient coverage; therefore, a brush coating method is used, with the coating amount controlled at 25g / m². 2 After coating, the material is dried at around 80℃ for 40 minutes. After drying, it is cured for 3 days to obtain a stain-resistant, deformation-resistant, skin-feel molded door panel. The functional resin, by weight, includes 35 parts waterborne polyurethane, 45 parts acrylic resin, 5 parts fluorine modifier dodecafluoroheptyl methacrylate, 5 parts perfluorooctyl hexanediol, 3 parts silicone modifier hydroxyl silicone oil, and 7 parts butylene glycol ester.

[0021] Compared with the prior art, the beneficial effects of the present invention are:

[0022] (1) Simple manufacturing process: The present invention uses polyethylene film as a balancing layer to replace the original liquid adhesive, saving the manual labor of applying glue and the time spent waiting for drying;

[0023] (2) Good bonding performance and stable product structure: The thin film adhesive (polyethylene film) used in this invention can bond well with the substrate surface due to its good thermoplasticity, forming a good coating effect on medium density fiberboard, avoiding the movement of moisture, and reducing the risk of moisture absorption and deformation.

[0024] Adding meltblown nonwoven fabric as a stabilizing layer under the first decorative layer can better improve the toughness and tensile strength of the impregnated paper, avoid cracking and deformation of the back side due to excessive tension of the PVC film on the front of the molded door panel, and better resist the stress difference caused by the different materials on the front and back sides; and the choice of this back structure reduces the production cost and process complexity compared to the thin PVC film on the back.

[0025] (3) Excellent surface physical and chemical properties, effective stain resistance and easy maintenance: The stain-resistant coating selected in this invention can be applied after the subsequent molding of the door panel, avoiding the surface treatment during the skin-feel film production process, which leads to increased hardness and brittleness, making it impossible to bend and shape. In addition, the surface film formation effect after coating and drying is good, which can effectively prevent stains and improve stain resistance. Attached image description:

[0026] Figure 1 It is a structural schematic diagram of the present invention. Detailed implementation method:

[0027] The present invention will be further described below with reference to the accompanying drawings and specific embodiments:

[0028] Example 1

[0029] like Figure 1As shown, the present invention provides a stain-resistant, deformation-resistant, skin-feel molded door panel, comprising a first decorative layer 1, a stabilizing layer 2, a first balancing layer 3, a substrate layer 4, a second balancing layer 5, a second decorative layer 6, and a stain-resistant layer 7 arranged sequentially from top to bottom.

[0030] The first decorative layer 1 on the back is melamine-impregnated paper, with no limit on its pattern; the stabilizing layer 2 is meltblown nonwoven fabric with a selected basis weight of 120g / m². 2 The thickness is 0.12 mm; the first balancing layer 3 and the second balancing layer 5 are both polyethylene films, with a thickness of 0.08 mm and a density of 0.8 g / cm³. 3 The fourth substrate layer is medium-density fiberboard with a density of 0.80 g / cm³. 3 The second decorative layer 6, with a thickness of 18mm, is a skin-feel film made of vacuum-formed PVC film with a thickness of 0.35mm. The stain-resistant layer 7 is a coating formed by coating with a high-molecular functional resin. In this embodiment, the high-molecular functional resin, by weight, includes 35 parts of waterborne polyurethane, 45 parts of acrylic resin, 5 parts of fluorinated modifier dodecafluoroheptyl methacrylate, 5 parts of perfluorooctylhexanediol, 3 parts of silicone modifier hydroxyl silicone oil, and 7 parts of butanediol ester. Among them, the waterborne polyurethane emulsion meets the following indicators: solid content 37±1%, pH value 6.0-7.0, viscosity 250-400mPa·s, elongation at break 1400%, and tensile strength 1.3MPa.

[0031] Melamine-impregnated paper, meltblown nonwoven fabric, and polyethylene film were selected and stacked sequentially on the surface of medium-density fiberboard (which had been milled and polished) as substrate layer 4. The composite was then hot-pressed using a single-layer hot press at a temperature of 130°C for 2 minutes and a unit pressure of 0.8 MPa.

[0032] After cutting the polyethylene film and skin-feel film to the same size, they are placed into a vacuum forming machine. The two are heated and the equipment cavity is pressurized. The temperature is set to 150℃, the positive pressure is set to 4.0 bar, the negative pressure is set to -0.7 bar, the preheating time is 40 seconds, the vacuum treatment is 8 seconds, and the pressurization treatment is 20 seconds, so that the vacuum-formed PVC film is wrapped on the board.

[0033] After the skin-feel film has stabilized on the sample surface, water-based polyurethane is applied to the molded door panel surface using a brushing method, with the coating amount controlled at 25g / m². 2 After coating, the product is dried at a low temperature for 40 minutes at 80℃. After drying, it is cured for 3 days to obtain a stain-resistant, deformation-resistant, skin-feel molded door panel.

[0034] Comparative example (using ordinary molded door panel structure and manufacturing process)

[0035] A single-layer hot press is used to directly press melamine-impregnated paper for the decorative finish onto the surface of the medium-density fiberboard (MDF) substrate. The substrate is then milled and sanded. A mixture of urea-formaldehyde resin and polyvinyl acetate (PVAc) adhesive is then manually applied. After drying and resting for 40 minutes, a 0.35mm thick vacuum-formed skin-feel film is selected from the market and placed in the equipment cavity along with a sample for heating and pressurization. The temperature is set at 150℃, with a positive pressure of 4.0 bar and a negative pressure of -0.7 bar. After a 40-second preheating time, a vacuuming time of 8 seconds is applied, followed by a 20-second pressurization process, allowing the PVC film to wrap around the board. After 3 days of curing, the skin-feel molded door panel is obtained.

[0036] To evaluate the superiority of Embodiment A of the present invention, the two sets of samples A and B prepared in this embodiment and the comparative example, respectively, were subjected to physicochemical property tests according to LY / T 1279-2020 "Polyvinyl Chloride Film-Faced Artificial Boards". The results are as follows:

[0037] Surface stain resistance: Sample A showed no obvious coffee stains; Sample B showed coffee-colored patches.

[0038] Surface resistance to thermal cycling: Sample A has a stable surface with no deformation or curling, while Sample B has a surface with peeling and curling of the skin-like film.

[0039] As can be seen, this invention uses a polyethylene film with a balancing layer instead of the original liquid adhesive, saving the manual labor of applying adhesive and the time spent waiting for drying, simplifying the processing. Simultaneously, the polyethylene film, due to its excellent thermoplasticity, can bond well with the substrate surface, forming a good covering effect on the medium-density fiberboard, preventing moisture movement, reducing the risk of moisture absorption and deformation, resulting in good bonding performance and stable product structure. Furthermore, adding a stabilizing layer of meltblown nonwoven fabric under the first decorative layer can better improve the toughness and tensile strength of the impregnated paper, preventing cracking and deformation on the back side due to excessive tension of the skin-feel film on the front of the molded door panel, and better resisting the stress difference caused by the different materials on the front and back sides. Moreover, this back structure reduces production costs and process complexity compared to using a thin PVC film for vacuum forming on the back. The stain-resistant coating can be applied after the molded door panel is formed, avoiding the surface treatment during the skin-feel film production process, which increases its hardness and brittleness, making it impossible to bend and shape. Furthermore, the coating forms a good film after drying, effectively preventing stains and improving stain resistance.

[0040] The above description only illustrates preferred embodiments of the present invention and should not be construed as limiting the scope of the claims. Any equivalent structural or procedural modifications made using this specification are included within the patent protection scope of the present invention.

Claims

1. A stain-resistant, deformation-resistant, skin-feel molded door panel, characterized in that: The material comprises, from top to bottom, a first finishing layer, a stabilizing layer, a first balancing layer, a substrate layer, a second balancing layer, a second finishing layer, and a stain-resistant layer. The substrate layer is medium-density fiberboard (MDF), the first finishing layer is melamine-impregnated paper, the stabilizing layer is meltblown nonwoven fabric, the first and second balancing layers are resin films, and the second finishing layer is a skin-feel film. The first finishing layer, the stabilizing layer, the first balancing layer, and the substrate layer are laminated on one side and then hot-pressed together; the skin-feel film and the second balancing layer are hot-pressed together with the substrate layer on the other side. The stain-resistant layer is coated with a high-molecular-weight functional resin, which, by weight, comprises 30-50 parts waterborne polyurethane, 30-60 parts acrylic resin, 2-8 parts fluoropolymer (dodecyl fluoroheptyl methacrylate), 3-5 parts perfluorooctyl hexanediol, 2-5 parts silicone (hydroxyl silicone oil), and 3-10 parts butylene glycol ester.

2. The stain-resistant, deformation-resistant, skin-feel molded door panel according to claim 1, characterized in that: The meltblown nonwoven fabric has a thickness of 0.15-0.25 mm and a basis weight of 80-180 g / m². 2 .

3. The stain-resistant, deformation-resistant, skin-feel molded door panel according to claim 1, characterized in that: The resin film is a polyethylene film with a thickness of 0.08-0.12 mm and a density of 0.8-0.9 g / cm³. 3 .

4. The stain-resistant, deformation-resistant, skin-feel molded door panel according to claim 1, characterized in that: The waterborne polyurethane emulsion meets the following requirements: solid content 37±1%, pH value 6.0-7.0, viscosity 250-400 mPa·s, elongation at break 1400%, and tensile strength 1.3 MPa.

5. The stain-resistant, deformation-resistant, skin-feel molded door panel according to claim 1, characterized in that: Medium density fiberboard (MDF) is a pre-treated MDF that has undergone milling and grinding.

6. The stain-resistant, deformation-resistant, skin-feel molded door panel according to claim 1, characterized in that: The skin-feel film is a vacuum-formed PVC film.

7. A manufacturing process for a stain-resistant, deformation-resistant, skin-feel molded door panel as described in any one of claims 1-6, characterized in that: Includes the following steps, Step 1: Select meltblown nonwoven fabric and polyethylene film of specific thickness and weight. Place melamine-impregnated paper, meltblown nonwoven fabric and polyethylene film on the surface of medium-density fiberboard that has been milled and polished in sequence. Combine the three together by hot press at a temperature of 120-140℃ for 2-3 minutes and a unit pressure of 0.8-1.0MPa. Step 2: After cutting the polyethylene film and skin-feel film to the same size, put them into the vacuum forming machine. Heat the polyethylene film and skin-feel film and pressurize the equipment cavity. Set the temperature between 130-160℃. Then inject compressed air to pressurize and soften the film, so that the skin-feel film covers the board. Step 3: After the skin-feel film has stabilized on the sample surface, apply a high-molecular functional resin to the molded door panel surface, controlling the coating amount to 15-25 g / m². 2 After coating, use low-temperature drying at 70-85℃ for 30-60 minutes; after drying, allow to cure for 2-5 days to obtain a stain-resistant, deformation-resistant, skin-feel molded door panel.

8. The manufacturing process of the stain-resistant, deformation-resistant, skin-feel molded door panel according to claim 7, characterized in that: Includes the following steps, Step 1, select a weight of 120g / m 2 Meltblown nonwoven fabric with a thickness of 0.12mm and a thickness of 0.08mm with a density of 0.8g / cm³. 3 The polyethylene film is made by placing melamine-impregnated paper, meltblown nonwoven fabric and polyethylene film in sequence on the surface of medium density fiberboard that has been milled and polished, and then bonding the three together by a single-layer hot press at a temperature of 130°C for 2 minutes and a unit pressure of 0.8MPa. Step 2, with a thickness of 0.08mm and a density of 0.8g / cm³. 3 After the polyethylene film and the 0.35mm thick skin-feel film are cut to the same size, they are placed into a vacuum forming machine. The polyethylene film and the skin-feel film are heated and the equipment cavity is pressurized. The temperature is set between 150℃, the positive pressure is set to 4.0 bar and the negative pressure to -0.7 bar. After a preheating time of 40 seconds, a vacuum treatment is performed for 8 seconds, followed by a pressurization treatment for 20 seconds, so that the PVC film is wrapped on the board. Step 3: After the skin-feel film has stabilized on the sample surface, apply a high-molecular functional resin to the molded door panel surface, controlling the coating amount to 25g / m². 2 After coating, dry at 80℃ for 40 minutes; After drying and curing for 3 days, a stain-resistant, deformation-resistant, skin-feel molded door panel can be obtained. The high-molecular functional resin, by weight, includes 35 parts waterborne polyurethane, 45 parts acrylic resin, 5 parts fluorine modifier dodecafluoroheptyl methacrylate, 5 parts perfluorooctyl hexanediol, 3 parts silicone modifier hydroxyl silicone oil, and 7 parts butylene glycol ester.

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