Composite environment-friendly decorative board and preparation method thereof

Abstract

The application discloses a composite environment-friendly decorative plate, which comprises a base material, at least one modification layer and a coating layer; the base material is wavy on both sides; the modification layer is fixed on at least one side of the base material through a hot-pressing process; the modification layer is a wood fiber plate with a three-dimensional cross-linked structure and is attached to the wavy surface of the base material; and the coating layer is coated on the outer sides of the base material and the modification layer and fills in the gaps between the base material and the modification layer. The plate structure and components are changed respectively, so that the toughness and strength of the existing decorative plate are improved, and the environmental protection performance is better.

Description

Technical Field

[0001] This invention belongs to the field of building decoration materials technology, specifically relating to a composite environmentally friendly decorative panel and its preparation method. Background Technology

[0002] Decorative building materials can be divided into two main parts: outdoor materials and indoor materials. Indoor materials can be further divided into five types: stone, boards, sheets, profiles, and wires. They can be used for interior and exterior wall decoration in general residences, shops, schools, warehouses, office buildings, etc. The main purpose of interior decoration is to protect the walls, enhance their strength and durability, extend their service life, and improve their functionality. As people's requirements for living environments become increasingly higher, the choice of indoor materials tends towards wood-based panels that combine environmental protection and aesthetics. Wood-based panels are further divided into solid wood panels and engineered wood panels. Solid wood panels are additive-free and environmentally friendly, but they are greatly affected by temperature and weather when used for decoration, are prone to moisture damage, and are difficult to maintain. Engineered wood panels are mainly made from solid wood, either broken down or cut, and then bonded together. The most common engineered wood panels on the market include MDF, particleboard, strawboard, and composite board. Engineered wood panels are easy to cut and process, have stable performance, and are not easily deformed by moisture, making them suitable for various applications. However, the processing of engineered wood panels requires the addition of adhesives, making them slightly less environmentally friendly than solid wood panels.

[0003] Composite panels, among engineered wood products, have become the most widely used and accepted type of decorative panel in recent years. Composite panels refer to panels made of two or more materials. In reality, the concept and manufacturing method of composite panels vary depending on the specific materials used. The materials that make up composite panels are diverse. Composite panels must adhere to green and environmentally friendly principles to ensure user health and effectively reduce pollution. Composite panels can reduce the amount of solid wood used while extending the lifespan of the panels. However, existing composite panels generally have limited environmental performance and impact resistance. They also lack good moisture absorption, mildew prevention, antibacterial and insect-repellent properties, and adsorption and purification functions, resulting in relatively limited functionality. Patent application number 201310186729.8, "Composite Structural Plywood and its Production Method," discloses a method of using polyethylene plastic film as the adhesive between the veneer and non-woven fabric, followed by hot pressing to obtain a composite structural plywood. Patent application number 201310739400.X, entitled "An Environmentally Friendly Bamboo-Wood Composite Board and Its Manufacturing Method," discloses the use of veneer and bamboo materials as the main raw materials, and plastic film or plastic woven fabric as the adhesive material. The veneer and bamboo materials are assembled according to the principle of symmetrical structure and pressed into bamboo-wood composite boards under certain temperature and pressure. The above patents all disclose the use of plastic film or plastic woven fabric or non-woven fabric as adhesive materials, which to some extent affects the physical and mechanical properties of the board, such as adhesive strength, internal bond strength and bending strength. Summary of the Invention

[0004] To address the problems existing in the prior art, this invention provides a composite environmentally friendly decorative panel and its preparation method. By changing the panel structure and composition, the toughness and strength of the existing decorative panel are improved, resulting in better environmental performance.

[0005] The technical solution of the present invention is as follows:

[0006] This invention provides a composite environmentally friendly decorative board, comprising a substrate, at least one decorative layer, and a coating layer; both sides of the substrate are wavy; the decorative layer is fixed to at least one side of the substrate by a hot-pressing process; the decorative layer is a wood fiber board with a three-dimensional cross-linked network structure that is bonded to the surface of the wavy substrate; the coating layer covers the outside of the substrate and the decorative layer and fills the gaps between the substrate and the decorative layer.

[0007] Furthermore, the coating layer comprises the following components by weight: 50-60 parts of composite waterborne resin emulsion, 10-20 parts of carbon nanotubes, 3-5 parts of magnesium-based bentonite, 3-5 parts of spodumene powder, 2-3 parts of talc powder, 2-3 parts of flame retardant, and 2-3 parts of additives.

[0008] Furthermore, the composite aqueous resin emulsion includes polyvinyl acetate emulsion, styrene-modified acrylic emulsion, and paraffin acrylic composite emulsion.

[0009] Furthermore, the wood fiberboard is a two-dimensional fiber sheet formed by processing a composite fiber body with wood fiber, polyether ester elastic fiber and silicon carbide fiber as the matrix, and then forming a three-dimensional cross-linked network matrix by superposition, braiding and winding.

[0010] Furthermore, the method for preparing the lignocellulosic board is as follows:

[0011] (1) After crushing wood fiber, polyether ester elastic fiber and silicon carbide fiber, place them in a coupling agent aqueous solution, take them out and dry them, and then pour them into a high-speed pulverizer and stir them thoroughly to obtain composite fiber material;

[0012] (2) The composite fiber material is mixed evenly with alginate and hydroxypropyl starch, and then the mixed material is injected into a mold and hot-pressed into a two-dimensional fiber sheet.

[0013] (3) Two-dimensional fiber sheets are formed by needle punching, superimposing, braiding and winding to form a three-dimensional cross-linked network matrix.

[0014] Furthermore, the porosity of the lignin fiber board is 30-40%, and the thickness is 10-30 mm.

[0015] Furthermore, the substrate is one of PVC rolls, bamboo fiber, or solid wood panels.

[0016] This invention also provides a method for preparing a composite environmentally friendly decorative panel, comprising the following steps:

[0017] S1. After mixing polyvinyl acetate emulsion, styrene-modified acrylic emulsion and paraffin acrylic composite emulsion, stir and heat to 80-100℃ to make the composite waterborne resin emulsion a uniform liquid.

[0018] S2. Add carbon nanotubes to a uniform composite water-based resin emulsion and stir to mix. After mixing thoroughly, lower the temperature of the mixture to 70-80℃, then add magnesium-based bentonite, wollastonite powder, talc powder, flame retardant and additives to the mixture. After mixing, stir to react for 1-3 hours, filter to obtain the coating for later use.

[0019] S3. The lignin fiberboard and the substrate are combined into a board blank through a hot pressing process, and then the pressure is reduced and the board is stretched to produce a composite board with a decorative layer.

[0020] S4. Fill the substrate with the modified layer obtained in step (3) with the coating obtained in step (2), and let the coating completely cover the substrate. After stabilizing for 12-16 hours, perform light curing to obtain a composite environmentally friendly decorative board.

[0021] Furthermore, in step S3, the lignocellulose board and the substrate are sent to a hot press for hot pressing at a temperature of 160-200℃, a pressure of 1.5-2.0MPa, and a time of 1.0-1.5min / mm. After hot pressing, the resulting composite board is cooled to below 60℃, and then the pressure is reduced to form S3. The lignocellulose board and the substrate are composited through a hot pressing process, and then the pressure is reduced to form a composite board with a decorative layer.

[0022] Furthermore, the light source used in step S4 for photocuring is ultraviolet light, and the photocuring time is 30-40 minutes.

[0023] Compared with the prior art, the present invention has the following beneficial effects:

[0024] 1. This invention provides a composite environmentally friendly decorative board, wherein a decorative layer is formed by hot pressing on at least one surface of the substrate. The decorative layer is a two-dimensional fiber sheet formed by processing a composite fiber body, and then a three-dimensional cross-linked network matrix is ​​formed by stacking, weaving and winding. When subjected to external impact, due to the presence of the three-dimensional cross-linked structure of the decorative layer, it can absorb the impact force after deformation, and can cope with different impact forces under different conditions, thereby improving the stability and bending strength of the board.

[0025] 2. In this invention, a coating is applied to the exterior of a substrate with a modified layer. The coating comprises a composite water-based resin emulsion, carbon nanotubes, magnesium-based bentonite, spodumene powder, talc powder, flame retardant, and additives. The film-forming substance is a composite water-based resin emulsion, using a mixture of polyvinyl acetate emulsion, styrene-modified acrylic emulsion, and paraffinic acrylic composite emulsion. By optimizing the formulation of the film-forming substance, the performance of the water-based coating after film formation is enhanced, improving the density of the film and the adhesion between the film and the substrate. This results in a coating with advantages such as good stability, waterproofing, gloss, and impact resistance. The addition of nano-scale carbon materials to the coating significantly improves its aging resistance, leak-proofness, and washability, thereby enhancing the coating's quality and extending its service life. Magnesium-based bentonite, containing Mg... 2+ It can help precipitate elements such as titanium that affect the whiteness of coatings, while magnesium-based bentonite introduces Mg... 2+ It has an emulsifying effect and is also beneficial to improve the whiteness of coatings; when different pigments are added to make colored coatings, it can improve the purity of the color; the addition of spodumene powder to coatings can improve the thermal stability of film-forming substances, enabling them to withstand rapid heating and cooling environmental changes, and making them applicable to a wider range of scenarios and environments.

[0026] 3. In this invention, the modification layer is mainly composed of wood fiber, polyether ester elastic fiber and silicon carbide fiber in wood cellulose board. The fiber is modified by coupling agent so that the modification layer formed by the composite fiber forms chemical bond connection and interpenetrating network structure with the polymer of the subsequent coating. This improves the interfacial adhesion performance between the modification layer fiber and the coating matrix, and at the same time provides the toughness and stability of the substrate. Detailed Implementation

[0027] The present invention will be further described below with reference to preferred embodiments. The endpoints and any values ​​of the ranges disclosed in the present invention are not limited to the precise ranges or values. These ranges or values ​​should be understood to include values ​​close to these ranges or values. For numerical ranges, the endpoint values ​​of the various ranges, the endpoint values ​​of the various ranges and individual point values, and individual point values ​​can be combined with each other to obtain one or more new numerical ranges. These numerical ranges should be considered as specifically disclosed herein.

[0028] Unless otherwise specified, all materials and reagents used in the following examples are commercially available.

[0029] Unless otherwise specified, the experimental methods described in the following examples are conventional methods.

[0030] Example 1

[0031] A composite environmentally friendly decorative board includes a substrate, a decorative layer, and a coating layer. The substrate is a PVC board with a wavy shape on both sides. The decorative layer is fixed to both sides of the substrate by a hot-pressing process. The decorative layer is a wood fiber board with a three-dimensional cross-linked network structure that is bonded to the surface of the wavy substrate. The wood fiber board is a two-dimensional fiber sheet formed by processing a composite fiber body with wood fiber, polyether ester elastic fiber, and silicon carbide fiber as the matrix, and then forming a three-dimensional cross-linked network matrix by stacking, weaving, and winding. The porosity of the wood fiber board is 30-40%, and the thickness is 10 mm. The coating layer covers the outside of the substrate and the decorative layer and fills the gaps between the substrate and the decorative layer.

[0032] In this embodiment, the coating layer comprises the following components by weight: 50 parts of composite waterborne resin emulsion, 10 parts of carbon nanotubes, 5 parts of magnesium-based bentonite, 3 parts of spodumene powder, 2 parts of talc powder, 2 parts of flame retardant, and 2 parts of additives. The additives are commonly used additives such as defoamers, dispersants, and leveling agents. The composite waterborne resin emulsion includes polyvinyl acetate emulsion, styrene-modified acrylic emulsion, and paraffin acrylic composite emulsion.

[0033] In this embodiment, the method for preparing the lignocellulosic board is as follows:

[0034] (1) After crushing wood fiber, polyether ester elastic fiber and silicon carbide fiber, place them in a coupling agent aqueous solution, take them out and dry them, and then pour them into a high-speed pulverizer and stir them thoroughly to obtain composite fiber material;

[0035] (2) The composite fiber material is mixed evenly with alginate and hydroxypropyl starch, and then the mixed material is injected into a mold and hot-pressed into a two-dimensional fiber sheet.

[0036] (3) Two-dimensional fiber sheets are formed by needle punching, superimposing, braiding and winding to form a three-dimensional cross-linked network matrix.

[0037] The preparation method of the composite environmentally friendly decorative board in this embodiment includes the following steps:

[0038] S1. After mixing polyvinyl acetate emulsion, styrene-modified acrylic emulsion and paraffin acrylic composite emulsion, stir and heat to 80°C to make the composite waterborne resin emulsion a uniform liquid.

[0039] S2. Add carbon nanotubes to a uniform composite water-based resin emulsion and stir to mix. After mixing thoroughly, lower the temperature of the mixture to 70°C, then add magnesium-based bentonite, wollastonite powder, talc powder, flame retardant and additives to the mixture. After mixing, stir to react for 1 hour, filter to obtain the coating for later use.

[0040] S3. The lignin fiberboard and the substrate are composited by hot pressing. The hot pressing temperature is 160℃, the hot pressing pressure is 1.5MPa, and the hot pressing time is 1.0min / mm. After hot pressing, the composite board is cooled to below 60℃ and then the pressure is reduced and the board is stretched to produce a composite board with a decorative layer.

[0041] S4. Fill the substrate with the modified layer obtained in step (3) with the coating obtained in step (2) and let the coating completely cover the substrate. After stabilizing for 12 hours, perform photocuring treatment. Use ultraviolet light as the light source and the photocuring time is 30 minutes to obtain a composite environmentally friendly decorative board.

[0042] Example 2

[0043] A composite environmentally friendly decorative board includes a substrate, a finishing layer, and a coating layer. The substrate is a solid wood board with a wavy shape on both sides. The finishing layer is fixed to both sides of the substrate by a hot-pressing process. The finishing layer is a wood fiber board with a three-dimensional cross-linked network structure that is bonded to the surface of the wavy substrate. The wood fiber board is a two-dimensional fiber sheet formed by processing a composite fiber body with wood fiber, polyether ester elastic fiber, and silicon carbide fiber as the matrix, and then forming a three-dimensional cross-linked network matrix by stacking, weaving, and winding. The porosity of the wood fiber board is 30-40%, and the thickness is 20 mm. The coating layer covers the outside of the substrate and the finishing layer and fills the gaps between the substrate and the finishing layer.

[0044] In this embodiment, the coating layer comprises the following components by weight: 60 parts of composite waterborne resin emulsion, 20 parts of carbon nanotubes, 3 parts of magnesium-based bentonite, 5 parts of spodumene powder, 2 parts of talc powder, 2 parts of flame retardant, and 3 parts of additives. The additives are commonly used additives such as defoamers, dispersants, and leveling agents. The composite waterborne resin emulsion includes polyvinyl acetate emulsion, styrene-modified acrylic emulsion, and paraffin acrylic composite emulsion.

[0045] In this embodiment, the preparation method of the lignocellulosic board is as in Example 1.

[0046] The preparation method of the composite environmentally friendly decorative board in this embodiment includes the following steps:

[0047] S1. After mixing polyvinyl acetate emulsion, styrene-modified acrylic emulsion and paraffin acrylic composite emulsion, stir and heat to 100°C to make the composite waterborne resin emulsion a uniform liquid.

[0048] S2. Add carbon nanotubes to a uniform composite water-based resin emulsion and stir to mix. After mixing thoroughly, lower the temperature of the mixture to 80°C, then add magnesium-based bentonite, wollastonite powder, talc powder, flame retardant and additives to the mixture. After mixing, stir to react for 3 hours, filter to obtain the coating for later use.

[0049] S3. The lignin fiberboard and the substrate are composited by hot pressing. The hot pressing temperature is 180℃, the hot pressing pressure is 2.0MPa, and the hot pressing time is 1.5min / mm. After hot pressing, the composite board is cooled to below 60℃ and then the pressure is reduced and the board is stretched to produce a composite board with a decorative layer.

[0050] S4. Fill the substrate with the modified layer obtained in step (3) with the coating obtained in step (2) and let the coating completely cover the substrate. After stabilizing for 16 hours, perform photocuring treatment. The light source used for photocuring treatment is ultraviolet light. The photocuring treatment time is 35 minutes. Finally, a composite environmentally friendly decorative board is obtained.

[0051] Example 3

[0052] A composite environmentally friendly decorative board includes a substrate, a finishing layer, and a coating layer. The substrate is bamboo fiber with a wavy shape on both sides. The finishing layer is fixed to both sides of the substrate by a hot-pressing process. The finishing layer is a wood fiber board with a three-dimensional cross-linked network structure that is bonded to the surface of the wavy substrate. The wood fiber board is a two-dimensional fiber sheet formed by processing a composite fiber body with wood fiber, polyether ester elastic fiber, and silicon carbide fiber as the matrix, and then forming a three-dimensional cross-linked network matrix by stacking, weaving, and winding. The porosity of the lignin fiber board is 30-40%, and the thickness is 30 mm. The coating layer covers the outside of the substrate and the finishing layer and fills the gaps between the substrate and the finishing layer.

[0053] In this embodiment, the coating layer comprises the following components by weight: 55 parts of composite waterborne resin emulsion, 15 parts of carbon nanotubes, 4 parts of magnesium-based bentonite, 4 parts of spodumene powder, 2 parts of talc powder, 3 parts of flame retardant, and 3 parts of additives. The additives are commonly used additives such as defoamers, dispersants, and leveling agents. The composite waterborne resin emulsion includes polyvinyl acetate emulsion, styrene-modified acrylic emulsion, and paraffin acrylic composite emulsion.

[0054] In this embodiment, the preparation method of the lignocellulosic board is as in Example 1.

[0055] The preparation method of the composite environmentally friendly decorative board in this embodiment includes the following steps:

[0056] S1. After mixing polyvinyl acetate emulsion, styrene-modified acrylic emulsion and paraffin acrylic composite emulsion, stir and heat to 90°C to make the composite waterborne resin emulsion a uniform liquid.

[0057] S2. Add carbon nanotubes to a uniform composite water-based resin emulsion and stir to mix. After mixing thoroughly, lower the temperature of the mixture to 80°C, then add magnesium-based bentonite, wollastonite powder, talc powder, flame retardant and additives to the mixture. After mixing, stir to react for 2 hours, filter to obtain the coating for later use.

[0058] S3. The lignin fiberboard and the substrate are composited by hot pressing. The hot pressing temperature is 200℃, the hot pressing pressure is 1.8MPa, and the hot pressing time is 1.2min / mm. After hot pressing, the composite board is cooled to below 60℃ and then the pressure is reduced and the board is stretched to produce a composite board with a decorative layer.

[0059] S4. Fill the substrate with the modified layer obtained in step (3) with the coating obtained in step (2) and let the coating completely cover the substrate. After stabilizing for 14 hours, perform photocuring treatment. The light source used for photocuring treatment is ultraviolet light, and the photocuring treatment time is 40 minutes. Finally, a composite environmentally friendly decorative board is obtained.

[0060] Example 4

[0061] The composite environmentally friendly decorative board in this embodiment differs from the board in Example 1 in that the decorative layer is only connected to one side of the substrate by a hot-pressing process. In this embodiment, the coating layer includes the following components by weight: 52 parts of composite water-based resin emulsion, 12 parts of carbon nanotubes, 3 parts of magnesium-based bentonite, 3 parts of spodumene powder, 3 parts of talc powder, 2 parts of flame retardant, and 2 parts of additives. The additives are commonly used additives such as defoamers, dispersants, and leveling agents. Among them, the composite water-based resin emulsion includes polyvinyl acetate emulsion, styrene-modified acrylic emulsion, and paraffin acrylic composite emulsion. The remaining materials, processes, and preparation steps are the same.

[0062] Performance testing:

[0063] Table 1 shows the mechanical properties of the composite environmentally friendly decorative panels prepared in Examples 1-4 above.

[0064]

[0065] Table 1. Other performance indicators of the composite environmentally friendly decorative panels prepared in Examples 1-4 above.

[0066]

[0067] In this invention, the natural corrosion resistance performance was tested according to the GB / T 13942.1-2009 standard. The composite boards prepared in Examples 1 to 4 above had a strength retention rate of more than 90.0% after immersion in a solution with a pH value of 2 to 11.

[0068] In this invention, the thermal stability test was conducted using the GB / T 1634.2-2004 standard. The heat distortion temperature of the composite plates in Examples 1 to 4 above all exceeded 130℃.

[0069] The composite environmentally friendly decorative panels of this invention were tested according to the TVOC values ​​specified in GN / T 27630-2011 "Guidelines for Evaluating Air Quality in Passenger Cars" and HJ / T400-2007 "Sampling and Determination Methods for Volatile Organic Compounds and Aldehydes and Ketones in Vehicle Interiors". As shown in the table, the TVOC values ​​of the panels prepared in Examples 1-4 are below 3000 μg / m³. 3 It has the characteristic of low VOC.

[0070] The above description is merely an embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent structural or procedural transformations made based on the content of the present invention specification, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of the present invention.

Claims

1. A composite environmentally friendly decorative panel, comprising a substrate, at least one decorative layer, and a coating layer, characterized in that: Both sides of the substrate are wavy; The decorative layer is fixed to at least one side of the substrate by a hot-pressing process; the decorative layer is a wood fiberboard with a three-dimensional cross-linked network structure that is bonded to the wavy surface of the substrate, and the porosity of the wood fiberboard is 30-40%. The wood fiberboard is formed by processing a composite fiber body with wood fiber, polyether ester elastic fiber and silicon carbide fiber as the matrix. Its preparation method includes: (1) After crushing wood fiber, polyether ester elastic fiber and silicon carbide fiber, place them in a coupling agent aqueous solution, take them out and dry them, and then pour them into a high-speed pulverizer and stir them thoroughly to obtain composite fiber material; (2) The composite fiber material is mixed evenly with alginate and hydroxypropyl starch, and then the mixed material is injected into a mold and hot-pressed into a two-dimensional fiber sheet; (3) Two-dimensional fiber sheets are formed into a three-dimensional cross-linked network matrix by needle punching, stacking, braiding and winding; The coating layer covers the outside of the substrate and the finishing layer and fills the gaps between the substrate and the finishing layer; the coating layer includes the following components by weight: 50-60 parts of composite waterborne resin emulsion, 10-20 parts of carbon nanotubes, 3-5 parts of magnesium-based bentonite, 3-5 parts of spodumene powder, 2-3 parts of talc powder, 2-3 parts of flame retardant and 2-3 parts of additives. The composite waterborne resin emulsion includes polyvinyl acetate emulsion, styrene-modified acrylic emulsion, and paraffin acrylic composite emulsion.

2. The composite environmentally friendly decorative panel as described in claim 1, characterized in that: The thickness of the wood fiberboard is 10-30 mm.

3. The composite environmentally friendly decorative panel as described in claim 1, characterized in that: The substrate is one of PVC rolls, bamboo fiber, or solid wood boards.

4. A method for preparing a composite environmentally friendly decorative panel as described in any one of claims 1 to 3, characterized in that, Includes the following steps: S1. After mixing polyvinyl acetate emulsion, styrene-modified acrylic emulsion and paraffin acrylic composite emulsion, stir and heat to 80-100℃ to make the composite waterborne resin emulsion a uniform liquid. S2. Add carbon nanotubes to a uniform composite water-based resin emulsion and stir to mix. After mixing thoroughly, lower the temperature of the mixture to 70-80℃, then add magnesium-based bentonite, spodumene powder, talc powder, flame retardant and additives to the mixture. After mixing, stir to react thoroughly for 1-3 hours, filter to obtain the coating for later use. S3. Wood fiberboard and substrate are composited by hot pressing, and then the pressure is reduced to stretch the board to produce a composite board with a decorative layer. S4. Fill the composite board with the decorative layer obtained in step S3 with the coating obtained in step S2, and let the coating completely cover the substrate. After stabilizing for 12-16 hours, perform light curing treatment to obtain a composite environmentally friendly decorative board.

5. The method for preparing a composite environmentally friendly decorative panel as described in claim 4, characterized in that: In step S3, the wood fiberboard and the substrate are sent to a hot press for hot pressing. The hot pressing temperature is 160-200℃, the hot pressing pressure is 1.5-2.0MPa, and the hot pressing time is 1.0-1.5 min / mm. After hot pressing, the resulting composite board is cooled to below 60℃, and then the pressure is reduced to obtain a composite board with a decorative layer.

6. The method for preparing a composite environmentally friendly decorative panel as described in claim 4, characterized in that: In step S4, the light source used for photocuring is ultraviolet light, and the photocuring time is 30-40 minutes.

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