A deep-textured decorative sheet and a method for producing the same

Abstract

This invention discloses a deep-textured decorative panel and its preparation method. The deep-textured decorative panel comprises: an inner core board, a first pad layer disposed on the upper surface of the inner core board, a first decorative layer disposed on the upper surface of the first pad layer, a second pad layer disposed on the lower surface of the inner core board, and a second decorative layer disposed on the lower surface of the second pad layer. The preparation method includes the following steps: S1, applying adhesive to the upper and lower surfaces of the inner core board respectively, and pressing the first and second pad layers together; S2, applying adhesive to the upper and lower surfaces of the material after pressing in step S1 respectively, and pressing the first and second decorative layers together; S3, deburring the outer surfaces of the first and second decorative layers, applying a modified coating, and drying to obtain the final product. The decorative panel obtained by this invention is aesthetically pleasing and exhibits good flame retardancy, impact resistance, water resistance, and overall excellent performance.

Description

Technical Field

[0001] This invention belongs to the field of sheet material preparation technology, specifically relating to a deep-textured decorative panel and its preparation method. Background Technology

[0002] Timber, as an environmentally friendly material, has become one of the world's major timber resources. However, with technological advancements and increased utilization of timber, its consumption is rising rapidly. The contradiction between the slow growth rate of trees and the ever-growing timber consumption is putting significant pressure on forest resources. Resource scarcity necessitates the conservation and rational use of timber. In this new era, engineered wood products have become one of the main building and decorative materials.

[0003] New building materials are an important component of the building materials industry and a burgeoning sector within it. With the increasing innovation in building materials and the growing emphasis on energy conservation in buildings, coupled with rising standards for building insulation, waterproofing, fireproofing, and decoration, as well as improved living conditions, the demand for new building materials will gradually increase. This demand necessitates that building materials not only possess excellent functionality but also meet people's pursuit of a comfortable life. Furthermore, with the rapid development of the national economy and the significant improvement in people's living standards, the industrial and civil building decoration industry has also developed rapidly. People have placed higher demands on their living environment, especially in interior decoration. People are no longer satisfied with simply having a place to live; more importantly, they desire safety, comfort, and other functions. The proportion of decoration costs in the overall construction project cost is increasing daily. Unfortunately, a large number of decoration materials used in current decoration work, especially building decoration boards currently on the domestic market, are generally flammable or combustible. The extensive use of these materials increases the fire load on buildings, creating hidden dangers for indoor fire safety.

[0004] Furthermore, with the improvement of people's living standards, various aesthetically pleasing and functional boards have been developed and used, such as those with impact resistance and earthquake resistance. In existing technologies, for example, patent document CN101992653B provides a fire-resistant decorative board that does not burn when exposed to fire, self-extinguishes after being removed from the fire, and exhibits good stability at high temperatures; however, it only focuses on flame-retardant properties. Another example is patent document CN105291243A, which provides a method for producing a moisture-proof ceiling decorative board. The adhesive used incorporates polyacrylate emulsion, polydimethylsiloxane, and EVA latex into urea-formaldehyde resin, improving the water resistance of the urea-formaldehyde resin. The resulting adhesive has good waterproof and moisture-proof properties, but the adhesive preparation process is complex.

[0005] Therefore, in the development of new decorative panels, this invention aims to provide a decorative panel with excellent overall performance. Summary of the Invention

[0006] In view of the shortcomings of the existing technology, the purpose of this invention is to provide a deep textured decorative panel and its preparation method. The resulting decorative panel is beautiful, and has good flame retardancy, impact resistance, water resistance and overall performance.

[0007] To achieve the above objectives, the present invention adopts the following technical solution:

[0008] In a first aspect, the present invention provides a method for preparing a deep textured decorative panel, wherein the deep textured decorative panel comprises: an inner core panel, a first pad layer disposed on the upper surface of the inner core panel, a first decorative layer disposed on the upper surface of the first pad layer, a second pad layer disposed on the lower surface of the inner core panel, and a second decorative layer disposed on the lower surface of the second pad layer.

[0009] The preparation method includes the following steps:

[0010] S1. Apply adhesive to the upper and lower surfaces of the inner core board respectively, and press the first padding layer and the second padding layer together.

[0011] S2. Apply adhesive to the upper and lower surfaces of the material after pressing in step S1, and press the first decorative layer and the second decorative layer together.

[0012] S3. After deburring the outer surfaces of the first and second decorative layers, apply a modified coating and let it dry to obtain the final product.

[0013] In the above technical solution, the decorative panel has a symmetrical structure, with an inner core panel in the middle and padding layers and decorative panels arranged symmetrically on both sides; the inner core panel can be common particleboard, solid wood board, etc. As a protective measure, a thin film can also be applied to the surface of the resulting board to protect it.

[0014] As a preferred embodiment of the technical solution of the present invention, both the first decorative panel and the second decorative panel are made of red cherry wood. The unique deep grain of red cherry wood makes the resulting decorative panels beautiful and attractive.

[0015] As a preferred embodiment of the technical solution of the present invention, in step S1, the adhesive is a polyurethane adhesive, and the amount of adhesive applied to both the upper and lower surfaces (i.e., the amount applied to one side) is 100-150 g / m². 2 The pressure plate is at room temperature, the pressure is 0.9–1.25 MPa, and the time is 4–8 hours.

[0016] As a preferred embodiment of the technical solution of the present invention, in step S2, the adhesive is melamine-modified urea-formaldehyde resin; the coating amount (i.e., the amount of adhesive applied to one side) on both the upper and lower surfaces is 90-120 g / m². 2 The temperature of the pressure plate is 90-110℃, the pressure is 0.8-1MPa, and the time is 30-60s.

[0017] As a preferred embodiment of the present invention, the preparation methods of the first pad and the second pad are the same, including the following steps:

[0018] A1. After treating fly ash with a modifier, it is filtered, washed and dried to obtain pre-modified fly ash.

[0019] A2. After mixing magnesium sulfate, magnesium oxide and water, a slurry is obtained. Modified fly ash obtained in step A1, mullite powder and chitosan are added to the slurry and stirred again to obtain a secondary slurry.

[0020] A3. The obtained secondary slurry is extruded to form an embryo, dried and cured to obtain the final product.

[0021] As a preferred embodiment of the technical solution of the present invention, in step A1, the modifier is obtained by mixing concentrated acid and hydrogen peroxide in a volume ratio of 1:1, and the mass concentration of hydrogen peroxide is 20-25%; the treatment time is 4-12 minutes, and the treatment temperature is room temperature.

[0022] As a preferred embodiment of the technical solution of the present invention, in step A2, the mass ratio of magnesium sulfate, magnesium oxide, water, modified fly ash, mullite, and chitosan is 1.5-4: 5.5-8: 10: 55-75: 4-8: 5-10.

[0023] As a preferred embodiment of the technical solution of the present invention, in step A3, the curing time is 2 to 4 days.

[0024] As a preferred embodiment of the present invention, in step S3, the coating amount of the modified coating is 0.05–0.2 mm; the preparation of the modified coating includes the following steps:

[0025] B1. Mix attapulgite with sodium hydroxide and treat it at high temperature. After treatment, grind and sieve through 50-150 mesh to obtain pre-modified attapulgite.

[0026] B2. Place the silica in a mixed solution of hydrogen peroxide and concentrated sulfuric acid and treat it at room temperature for 1 to 6 minutes. After treatment, filter, wash and dry to obtain pre-modified silica.

[0027] B3. Add the pre-modified attapulgite clay obtained in step B1 to KH550, stir evenly, then add it to phenolic resin, stir evenly again, then add the pre-modified silica obtained in step B2, stir evenly, and the modified coating is obtained.

[0028] As a preferred embodiment of the technical solution of the present invention, in step B1, the mass ratio of attapulgite clay to sodium hydroxide is 1:0.5-0.9; the high-temperature treatment temperature is 780-800℃, and the treatment time is 0.5-4h.

[0029] In step B2, the volume ratio of hydrogen peroxide to concentrated sulfuric acid is 1:1, the mass concentration of hydrogen peroxide is 26-30%, and the volume ratio of silicon dioxide to the mixed solution is 1g:8-15mL.

[0030] In step B3, the mass ratio of pre-modified attapulgite, KH550, phenolic resin, and pre-modified silica is 10-15:0.5-1:65:4-7.

[0031] Secondly, the present invention also aims to protect the deep-textured decorative panels prepared by the above method.

[0032] Compared with the prior art, the present invention has the following beneficial effects:

[0033] (1) The present invention provides a method for preparing a deep textured decorative panel, which uses an inner core board as the main body and presses a pad and a decorative panel on both sides respectively. The use of the pad reduces the amount of wood used and also improves the performance of the decorative panel.

[0034] (2) The present invention provides a method for preparing a deep textured decorative panel, which mainly uses common adhesives and conventional pressing processes to produce the decorative panel. It is simple and easy to operate.

[0035] (3) The present invention provides a method for preparing a deep textured decorative panel. The preparation of the underlayment uses magnesium sulfate and magnesium oxide as raw materials, which gives the underlayment excellent flame retardant properties. The underlayment is made from inorganic materials, which reduces the amount of wood used. At the same time, a large amount of fly ash and a small amount of chitosan and mullite are mixed in the raw materials. Fly ash is a type of by-product. Its utilization has great economic value and environmental significance. In the process of use, the fly ash is treated with mixed acid to improve its specific surface area and reactivity. The modified fly ash has a better effect in the underlayment. The reason may be that after the reactivity of the modified fly ash is improved, the small amount of silicates and acidic oxides it contains can react with magnesium sulfate and magnesium oxide, which improves the comprehensive performance of the material system. Of course, the modified fly ash also introduces hydroxyl groups, which is conducive to the composite compatibility of fly ash and chitosan, reduces the agglomeration tendency of fly ash, and can further improve the comprehensive performance of the underlayment. It is worth noting that the use of a small amount of chitosan provides antibacterial effects and also allows it to coordinate with magnesium ions to form a robust cross-linked structure, further improving the performance of the padding layer. The addition of mullite provides both flame retardancy and crack resistance, enhancing the padding layer's performance. In summary, the synergistic use of these substances results in a padding layer with good impact resistance, impact toughness, high bonding strength, and excellent overall performance.

[0036] (3) The present invention provides a method for preparing a deep textured decorative panel. After the panel is prepared, a specific coating is applied. The coating uses phenolic resin as a film-forming agent and attapulgite and silica as additives. During use, the attapulgite and silica are treated to improve their agglomeration tendency and performance. Specifically, the attapulgite is subjected to high-temperature alkali treatment, which is beneficial to enrich its pores and facilitates its subsequent KH550 treatment and composite with silica. Silica is treated with mixed acid, just like fly ash, to improve surface activity and introduce hydroxyl groups. The attapulgite modified with KH550 is rich in amino groups. Its rich pores after high-temperature alkali treatment are conducive to forming a hydrogen bond system with silica, forming a stable cross-linking system, filling the dense phenolic resin film, improving the coating effect, and thus improving the mechanical properties and fire resistance of the panel.

[0037] In summary, the decorative panel provided by this invention is aesthetically pleasing and has good overall performance, thus possessing promising market prospects. Detailed Implementation

[0038] The embodiments of the present invention are described in detail below. All embodiments are exemplary and intended to explain the present invention, and should not be construed as limiting the present invention.

[0039] In this invention, the phenolic resin is grade F51; the concentrated sulfuric acid has a mass fraction of 98%; the polyurethane adhesive can be a commonly available product, such as the one sold by Shenzhen Yoshida Chemical Co., Ltd.; the melamine-modified urea-formaldehyde resin can be a commonly available product, such as the product with the grade GUUDPOLY MUF 207D sold by Gudeyuan Kente Technology (Beijing) Co., Ltd.; and the silica has a particle size of approximately 50 nm.

[0040] The inner core layer uses particleboard as raw material; the first and second decorative panels are both made of red cherry wood; the thickness of the inner core panel can be 3mm, the thickness of the decorative veneer is 0.2mm, the thickness of the padding veneer is 0.8mm, and the total thickness of the decorative panels is controlled at around 5mm; of course, it can also be customized according to the customer's needs.

[0041] In this invention, all other undescribed aspects are conventional methods (such as coating methods) known to those skilled in the art; materials without stated sources are all commercially available.

[0042] Example 1

[0043] A method for preparing a deep textured decorative panel, wherein the deep textured decorative panel comprises: an inner core board, a first pad layer disposed on the upper surface of the inner core board, a first decorative layer disposed on the upper surface of the first pad layer, a second pad layer disposed on the lower surface of the inner core board, and a second decorative layer disposed on the lower surface of the second pad layer.

[0044] The preparation method includes the following steps:

[0045] S1. Apply a single-sided coating of 125g / m² to the upper and lower surfaces of the inner core board. 2 Polyurethane adhesive was applied to both layers, and the first and second pads were then pressed together. The pressing process parameters were: room temperature, 1.15 MPa pressure, and 5.5 h time.

[0046] S2. Apply a single-sided coating of 115 g / m² to the upper and lower surfaces of the material after pressing in step S1. 2 Melamine-modified urea-formaldehyde resin was applied to both the first and second decorative layers, and then the layers were pressed together. The pressing process parameters were: temperature 105℃, pressure 0.95MPa, and time 35s.

[0047] S3. After deburring the outer surfaces of the first and second decorative layers, apply a 0.1mm layer of modified coating and let it dry to obtain the final product.

[0048] The first and second cushion layers are prepared using the same method, including the following steps:

[0049] A1. Fly ash is treated with a modifier (a mixture of concentrated sulfuric acid and hydrogen peroxide in a volume ratio of 1:1, with a hydrogen peroxide concentration of 20wt%) for 5 minutes, and then filtered, washed, and dried to obtain pre-modified fly ash.

[0050] A2. Magnesium sulfate, magnesium oxide and water are mixed and stirred to obtain a slurry. Modified fly ash obtained in step A1, mullite powder and chitosan are added to the slurry and stirred again to obtain a secondary slurry. The mass ratio of magnesium sulfate, magnesium oxide, water, modified fly ash, mullite and chitosan is 2.5:6:10:60:5:5.5.

[0051] A3. The obtained secondary slurry is extruded to form a preform (400×400mm), dried and cured for 3 days to obtain the final product.

[0052] The preparation of the modified coating includes the following steps:

[0053] B1. Mix attapulgite and sodium hydroxide at a mass ratio of 1:0.6 and treat at 790℃ for 1.5h. After treatment, grind and sieve through 100 mesh to obtain pre-modified attapulgite.

[0054] B2. According to the dosage of 1g:10mL, place the silica in a mixed solution of hydrogen peroxide and concentrated sulfuric acid (volume ratio 1:1, hydrogen peroxide concentration 25wt%) and treat it at room temperature for 3min; after treatment, filter, wash and dry to obtain pre-modified silica.

[0055] B3. Add the pre-modified attapulgite obtained in step B1 to KH550, stir evenly, then add it to phenolic resin, stir evenly again, then add the pre-modified silica obtained in step B2, stir evenly, and the modified coating is obtained; wherein, the mass ratio of pre-modified attapulgite, KH550, phenolic resin and pre-modified silica is 12:0.6:65:5.

[0056] Example 2

[0057] A method for preparing a deep textured decorative panel, wherein the deep textured decorative panel comprises: an inner core board, a first pad layer disposed on the upper surface of the inner core board, a first decorative layer disposed on the upper surface of the first pad layer, a second pad layer disposed on the lower surface of the inner core board, and a second decorative layer disposed on the lower surface of the second pad layer.

[0058] The preparation method includes the following steps:

[0059] S1. Apply a single-sided coating of 125g / m² to the upper and lower surfaces of the inner core board. 2 Polyurethane adhesive was applied to both layers, and the first and second pads were then pressed together. The pressing process parameters were: room temperature, 1.15 MPa pressure, and 5.5 h time.

[0060] S2. Apply a single-sided coating of 115 g / m² to the upper and lower surfaces of the material after pressing in step S1. 2 Melamine-modified urea-formaldehyde resin was applied to both the first and second decorative layers, and then the layers were pressed together. The pressing process parameters were: temperature 105℃, pressure 0.95MPa, and time 35s.

[0061] S3. After deburring the outer surfaces of the first and second decorative layers, apply a 0.1mm layer of modified coating and let it dry to obtain the final product.

[0062] The first and second cushion layers are prepared using the same method, including the following steps:

[0063] A1. Fly ash is treated with a modifier (a mixture of concentrated sulfuric acid and hydrogen peroxide in a volume ratio of 1:1, with a hydrogen peroxide concentration of 20wt%) for 4 minutes, and then filtered, washed, and dried to obtain pre-modified fly ash.

[0064] A2. Magnesium sulfate, magnesium oxide, and water are mixed and stirred to obtain a slurry. Modified fly ash obtained in step A1, mullite powder, and chitosan are added to the slurry, and stirred again to obtain a secondary slurry. The mass ratio of magnesium sulfate, magnesium oxide, water, modified fly ash, mullite, and chitosan is 2.5:6.5:10:65:4.5:6.

[0065] A3. The obtained secondary slurry is extruded to form a preform (400×400mm), dried and cured for 3 days to obtain the final product.

[0066] The preparation of the modified coating includes the following steps:

[0067] B1. Mix attapulgite and sodium hydroxide at a mass ratio of 1:0.55 and treat at 795℃ for 1 hour. After treatment, grind and sieve through 100 mesh to obtain pre-modified attapulgite.

[0068] B2. According to the dosage of 1g:12mL, place the silica in a mixed solution of hydrogen peroxide and concentrated sulfuric acid (volume ratio 1:1, hydrogen peroxide concentration 25wt%) and treat it at room temperature for 3min; after treatment, filter, wash and dry to obtain pre-modified silica.

[0069] B3. Add the pre-modified attapulgite obtained in step B1 to KH550, stir evenly, then add it to phenolic resin, stir evenly again, then add the pre-modified silica obtained in step B2, stir evenly, and the modified coating is obtained; wherein, the mass ratio of pre-modified attapulgite, KH550, phenolic resin and pre-modified silica is 12:0.65:65:5.5.

[0070] Example 3

[0071] A method for preparing a deep textured decorative panel, wherein the deep textured decorative panel comprises: an inner core board, a first pad layer disposed on the upper surface of the inner core board, a first decorative layer disposed on the upper surface of the first pad layer, a second pad layer disposed on the lower surface of the inner core board, and a second decorative layer disposed on the lower surface of the second pad layer.

[0072] The preparation method includes the following steps:

[0073] S1. Apply a single-sided coating of 125g / m² to the upper and lower surfaces of the inner core board. 2 Polyurethane adhesive was applied to both layers, and the first and second pads were then pressed together. The pressing process parameters were: room temperature, 1.15 MPa pressure, and 5.5 h time.

[0074] S2. Apply a single-sided coating of 115 g / m² to the upper and lower surfaces of the material after pressing in step S1. 2Melamine-modified urea-formaldehyde resin was applied to both the first and second decorative layers, and then the layers were pressed together. The pressing process parameters were: temperature 105℃, pressure 0.95MPa, and time 35s.

[0075] S3. After deburring the outer surfaces of the first and second decorative layers, apply a 0.1mm layer of modified coating and let it dry to obtain the final product.

[0076] The first and second cushion layers are prepared using the same method, including the following steps:

[0077] A1. Fly ash is treated with a modifier (a mixture of concentrated sulfuric acid and hydrogen peroxide in a volume ratio of 1:1, with a hydrogen peroxide concentration of 20wt%) for 4 minutes, and then filtered, washed, and dried to obtain pre-modified fly ash.

[0078] A2. Magnesium sulfate, magnesium oxide, and water are mixed and stirred to obtain a slurry. Modified fly ash obtained in step A1, mullite powder, and chitosan are added to the slurry, and stirred again to obtain a secondary slurry. The mass ratio of magnesium sulfate, magnesium oxide, water, modified fly ash, mullite, and chitosan is 2.5:5.5:10:65:5:5.5.

[0079] A3. The obtained secondary slurry is extruded to form a preform (400×400mm), dried and cured for 3 days to obtain the final product.

[0080] The preparation of the modified coating includes the following steps:

[0081] B1. Mix attapulgite and sodium hydroxide at a mass ratio of 1:0.65 and treat at 790℃ for 2 hours. After treatment, grind and sieve through 100 mesh to obtain pre-modified attapulgite.

[0082] B2. According to the dosage of 1g:11mL, place the silica in a mixed solution of hydrogen peroxide and concentrated sulfuric acid (volume ratio 1:1, hydrogen peroxide concentration 25wt%) and treat it at room temperature for 3min; after treatment, filter, wash and dry to obtain pre-modified silica.

[0083] B3. Add the pre-modified attapulgite obtained in step B1 to KH550, stir evenly, then add it to phenolic resin, stir evenly again, then add the pre-modified silica obtained in step B2, stir evenly, and the modified coating is obtained; wherein, the mass ratio of pre-modified attapulgite, KH550, phenolic resin and pre-modified silica is 11.5:0.55:65:6.

[0084] Comparative Example 1

[0085] Compared with Example 1, the preparation method of the first pad and the second pad in Comparative Example 1 omits step A1. Specifically, a method for preparing a deep textured decorative panel is provided, wherein the deep textured decorative panel is composed of: an inner core board, a first pad disposed on the upper surface of the inner core board, a first decorative layer disposed on the upper surface of the first pad, a second pad disposed on the lower surface of the inner core board, and a second decorative layer disposed on the lower surface of the second pad.

[0086] The preparation method includes the following steps:

[0087] S1. Apply a single-sided coating of 125g / m² to the upper and lower surfaces of the inner core board. 2 Polyurethane adhesive was applied to both layers, and the first and second pads were then pressed together. The pressing process parameters were: room temperature, 1.15 MPa pressure, and 5.5 h time.

[0088] S2. Apply a single-sided coating of 115 g / m² to the upper and lower surfaces of the material after pressing in step S1. 2 Melamine-modified urea-formaldehyde resin was applied to both the first and second decorative layers, and then the layers were pressed together. The pressing process parameters were: temperature 105℃, pressure 0.95MPa, and time 35s.

[0089] S3. After deburring the outer surfaces of the first and second decorative layers, apply a 0.1mm layer of modified coating and let it dry to obtain the final product.

[0090] The first and second cushion layers are prepared using the same method, including the following steps:

[0091] A1. Magnesium sulfate, magnesium oxide and water are mixed and stirred to obtain a slurry. Fly ash, mullite powder and chitosan are added to the slurry and stirred again to obtain a secondary slurry. The mass ratio of magnesium sulfate, magnesium oxide, water, fly ash, mullite and chitosan is 2.5:6:10:60:5:5.5.

[0092] A2. The obtained secondary slurry is extruded to form a preform (400×400mm), dried and cured for 3 days to obtain the final product.

[0093] The preparation of the modified coating includes the following steps:

[0094] B1. Mix attapulgite and sodium hydroxide at a mass ratio of 1:0.6 and treat at 790℃ for 1.5h. After treatment, grind and sieve through 100 mesh to obtain pre-modified attapulgite.

[0095] B2. According to the dosage of 1g:10mL, place the silica in a mixed solution of hydrogen peroxide and concentrated sulfuric acid (volume ratio 1:1, hydrogen peroxide concentration 25wt%) and treat it at room temperature for 3min; after treatment, filter, wash and dry to obtain pre-modified silica.

[0096] B3. Add the pre-modified attapulgite obtained in step B1 to KH550, stir evenly, then add it to phenolic resin, stir evenly again, then add the pre-modified silica obtained in step B2, stir evenly, and the modified coating is obtained; wherein, the mass ratio of pre-modified attapulgite, KH550, phenolic resin and pre-modified silica is 12:0.6:65:5.

[0097] Comparative Example 2

[0098] Compared with Example 1, the preparation method of the first and second pads in Comparative Example 2 omits the use of chitosan. Specifically, a method for preparing a deep textured decorative panel is provided, wherein the deep textured decorative panel is composed of: an inner core board, a first pad disposed on the upper surface of the inner core board, a first decorative layer disposed on the upper surface of the first pad, a second pad disposed on the lower surface of the inner core board, and a second decorative layer disposed on the lower surface of the second pad.

[0099] The preparation method includes the following steps:

[0100] S1. Apply a single-sided coating of 125g / m² to the upper and lower surfaces of the inner core board. 2 Polyurethane adhesive was applied to both layers, and the first and second pads were then pressed together. The pressing process parameters were: room temperature, 1.15 MPa pressure, and 5.5 h time.

[0101] S2. Apply a single-sided coating of 115 g / m² to the upper and lower surfaces of the material after pressing in step S1. 2 Melamine-modified urea-formaldehyde resin was applied to both the first and second decorative layers, and then the layers were pressed together. The pressing process parameters were: temperature 105℃, pressure 0.95MPa, and time 35s.

[0102] S3. After deburring the outer surfaces of the first and second decorative layers, apply a 0.1mm layer of modified coating and let it dry to obtain the final product.

[0103] The first and second cushion layers are prepared using the same method, including the following steps:

[0104] A1. Fly ash is treated with a modifier (a mixture of concentrated sulfuric acid and hydrogen peroxide in a volume ratio of 1:1, with a hydrogen peroxide concentration of 20wt%) for 5 minutes, and then filtered, washed, and dried to obtain pre-modified fly ash.

[0105] A2. Magnesium sulfate, magnesium oxide and water are mixed and stirred to obtain a slurry. Modified fly ash and mullite powder obtained in step A1 are added to the slurry and stirred again to obtain a secondary slurry. The mass ratio of magnesium sulfate, magnesium oxide, water, modified fly ash and mullite is 2.5:6:10:60:5.

[0106] A3. The obtained secondary slurry is extruded to form a preform (400×400mm), dried and cured for 3 days to obtain the final product.

[0107] The preparation of the modified coating includes the following steps:

[0108] B1. Mix attapulgite and sodium hydroxide at a mass ratio of 1:0.6 and treat at 790℃ for 1.5h. After treatment, grind and sieve through 100 mesh to obtain pre-modified attapulgite.

[0109] B2. According to the dosage of 1g:10mL, place the silica in a mixed solution of hydrogen peroxide and concentrated sulfuric acid (volume ratio 1:1, hydrogen peroxide concentration 25wt%) and treat it at room temperature for 3min; after treatment, filter, wash and dry to obtain pre-modified silica.

[0110] B3. Add the pre-modified attapulgite obtained in step B1 to KH550, stir evenly, then add it to phenolic resin, stir evenly again, then add the pre-modified silica obtained in step B2, stir evenly, and the modified coating is obtained; wherein, the mass ratio of pre-modified attapulgite, KH550, phenolic resin and pre-modified silica is 12:0.6:65:5.

[0111] Comparative Example 3

[0112] Compared with Example 1, Comparative Example 3 omits the modification of attapulgite in the modified coating, that is, attapulgite is used directly without any modification; specifically, a method for preparing a deep textured decorative panel, wherein the deep textured decorative panel is composed of: an inner core board, a first pad layer disposed on the upper surface of the inner core board, a first decorative layer disposed on the upper surface of the first pad layer, a second pad layer disposed on the lower surface of the inner core board, and a second decorative layer disposed on the lower surface of the second pad layer;

[0113] The preparation method includes the following steps:

[0114] S1. Apply a single-sided coating of 125g / m² to the upper and lower surfaces of the inner core board. 2 Polyurethane adhesive was applied to both layers, and the first and second pads were then pressed together. The pressing process parameters were: room temperature, 1.15 MPa pressure, and 5.5 h time.

[0115] S2. Apply a single-sided coating of 115 g / m² to the upper and lower surfaces of the material after pressing in step S1. 2 Melamine-modified urea-formaldehyde resin was applied to both the first and second decorative layers, and then the layers were pressed together. The pressing process parameters were: temperature 105℃, pressure 0.95MPa, and time 35s.

[0116] S3. After deburring the outer surfaces of the first and second decorative layers, apply a 0.1mm layer of modified coating and let it dry to obtain the final product.

[0117] The first and second cushion layers are prepared using the same method, including the following steps:

[0118] A1. Fly ash is treated with a modifier (a mixture of concentrated sulfuric acid and hydrogen peroxide in a volume ratio of 1:1, with a hydrogen peroxide concentration of 20wt%) for 5 minutes, and then filtered, washed, and dried to obtain pre-modified fly ash.

[0119] A2. Magnesium sulfate, magnesium oxide and water are mixed and stirred to obtain a slurry. Modified fly ash obtained in step A1, mullite powder and chitosan are added to the slurry and stirred again to obtain a secondary slurry. The mass ratio of magnesium sulfate, magnesium oxide, water, modified fly ash, mullite and chitosan is 2.5:6:10:60:5:5.5.

[0120] A3. The obtained secondary slurry is extruded to form a preform (400×400mm), dried and cured for 3 days to obtain the final product.

[0121] The preparation of the modified coating includes the following steps:

[0122] B1. According to the dosage of 1g:10mL, place the silica in a mixed solution of hydrogen peroxide and concentrated sulfuric acid (volume ratio 1:1, hydrogen peroxide concentration 25wt%) and treat it at room temperature for 3min; after treatment, filter, wash and dry to obtain pre-modified silica.

[0123] B2. Add attapulgite to KH550, stir evenly, then add to phenolic resin, stir evenly again, then add the pre-modified silica obtained in step B1, stir evenly, and the modified coating is obtained; wherein, the mass ratio of attapulgite, KH550, phenolic resin and pre-modified silica is 12:0.6:65:5.

[0124] Comparative Example 4

[0125] Compared with Example 1, Comparative Example 4 omits the modification of silicon dioxide, that is, silicon dioxide is used directly. Specifically, a method for preparing a deep textured decorative panel is provided, wherein the deep textured decorative panel is composed of: an inner core board, a first pad layer disposed on the upper surface of the inner core board, a first decorative layer disposed on the upper surface of the first pad layer, a second pad layer disposed on the lower surface of the inner core board, and a second decorative layer disposed on the lower surface of the second pad layer.

[0126] The preparation method includes the following steps:

[0127] S1. Apply a single-sided coating of 125g / m² to the upper and lower surfaces of the inner core board. 2 Polyurethane adhesive was applied to both layers, and the first and second pads were then pressed together. The pressing process parameters were: room temperature, 1.15 MPa pressure, and 5.5 h time.

[0128] S2. Apply a single-sided coating of 115 g / m² to the upper and lower surfaces of the material after pressing in step S1. 2 Melamine-modified urea-formaldehyde resin was applied to both the first and second decorative layers, and then the layers were pressed together. The pressing process parameters were: temperature 105℃, pressure 0.95MPa, and time 35s.

[0129] S3. After deburring the outer surfaces of the first and second decorative layers, apply a 0.1mm layer of modified coating and let it dry to obtain the final product.

[0130] The first and second cushion layers are prepared using the same method, including the following steps:

[0131] A1. Fly ash is treated with a modifier (a mixture of concentrated sulfuric acid and hydrogen peroxide in a volume ratio of 1:1, with a hydrogen peroxide concentration of 20wt%) for 5 minutes, and then filtered, washed, and dried to obtain pre-modified fly ash.

[0132] A2. Magnesium sulfate, magnesium oxide and water are mixed and stirred to obtain a slurry. Modified fly ash obtained in step A1, mullite powder and chitosan are added to the slurry and stirred again to obtain a secondary slurry. The mass ratio of magnesium sulfate, magnesium oxide, water, modified fly ash, mullite and chitosan is 2.5:6:10:60:5:5.5.

[0133] A3. The obtained secondary slurry is extruded to form a preform (400×400mm), dried and cured for 3 days to obtain the final product.

[0134] The preparation of the modified coating includes the following steps:

[0135] B1. Mix attapulgite and sodium hydroxide at a mass ratio of 1:0.6 and treat at 790℃ for 1.5h. After treatment, grind and sieve through 100 mesh to obtain pre-modified attapulgite.

[0136] B2. Add the pre-modified attapulgite obtained in step B1 to KH550, stir evenly, then add it to phenolic resin, stir evenly again, then add silica and stir evenly to obtain the modified coating; wherein, the mass ratio of pre-modified attapulgite, KH550, phenolic resin and silica is 12:0.6:65:5.

[0137] First, the intermediate board products obtained after step S1 in Example 1 and Comparative Examples 1-2 were subjected to performance testing.

[0138] 1) Impact toughness test: The room temperature impact toughness and low temperature impact toughness test shall be conducted in accordance with GB / T 17657-2022.

[0139] 2) Screw holding force test: The screw holding force from the front and the screw holding force from the side are tested in accordance with GB / T 17657-2022.

[0140] 3) Elastic modulus test: Performed in accordance with GB / T 17657-2022.

[0141] 4) Adhesion strength test: Refer to GB / T 17657-2022.

[0142] 5) Impact resistance test: Conducted in accordance with GB / T 17657-2022.

[0143] Table 1. Performance Test of Intermediate Plate

[0144]

[0145] Next, the performance of the deep-textured decorative panels prepared in Example 1 and Comparative Examples 2-4 was tested, and the specific methods are as follows:

[0146] 1) Flame retardancy test: Flame retardancy rating is classified according to GB8624-2012 and tested according to GB / T 8626-2007; oxygen index test is conducted according to GB / T 2406-2009.

[0147] 2) Impregnation peel test: The test shall be conducted in accordance with GB / T17657-2022, and the board shall be cut to a size of 75×75mm.

[0148] 3) Abrasion resistance test: Refer to Method 3 in GB / T17657-2022. Rotate 200 revolutions, weigh the plate before and after grinding, calculate the difference, and obtain the wear amount.

[0149] Table 2 Performance Test of Decorative Panels

[0150] Flame retardant rating Oxygen Index Impregnation and peeling Loss / g Example 1 Grade A 36 qualified 0.201 Comparative Example 3 Grade A 32 qualified 0.254 Comparative Example 4 Grade A 28 Unqualified 0.386

[0151] As can be seen from Table 1, the padding layer prepared in this application has good impact resistance, impact toughness, elastic modulus and bonding strength, which ensures the performance of the prepared decorative panel; as can be seen from the test results in Table 2, the decorative panel prepared in this application has good fire resistance, low loss, and excellent comprehensive performance.

[0152] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A method for preparing a deep-textured decorative panel, characterized in that, The deep textured decorative panel is composed of: an inner core panel, a first pad layer disposed on the upper surface of the inner core panel, a first decorative layer disposed on the upper surface of the first pad layer, a second pad layer disposed on the lower surface of the inner core panel, and a second decorative layer disposed on the lower surface of the second pad layer. The preparation method includes the following steps: S1. Apply adhesive to the upper and lower surfaces of the inner core board respectively, and press the first padding layer and the second padding layer together. S2. Apply adhesive to the upper and lower surfaces of the material after pressing in step S1, and press the first decorative layer and the second decorative layer together. S3. After deburring the outer surfaces of the first and second decorative layers, apply a modified coating and let it dry to obtain the final product. The first and second cushion layers are prepared using the same method, including the following steps: A1. After treating fly ash with a modifier, it is filtered, washed and dried to obtain pre-modified fly ash. A2. After mixing magnesium sulfate, magnesium oxide and water, a slurry is obtained. Modified fly ash obtained in step A1, mullite powder and chitosan are added to the slurry and stirred again to obtain a secondary slurry. A3. The obtained secondary slurry is extruded to form an embryo, dried and cured to obtain the final product; In step A1, the modifier is obtained by mixing concentrated sulfuric acid and hydrogen peroxide in a volume ratio of 1:1, with the hydrogen peroxide having a mass concentration of 20-25%; the treatment time is 4-12 minutes, and the treatment temperature is room temperature. In step S3, the coating amount of the modified coating is 0.05~0.2mm; the preparation of the modified coating includes the following steps: B1. After mixing attapulgite with sodium hydroxide, the mixture is treated at high temperature. After treatment, it is ground and sieved through a 50-150 mesh to obtain pre-modified attapulgite. B2. Place the silica in a mixed solution of hydrogen peroxide and concentrated sulfuric acid and treat it at room temperature for 1-6 minutes. After treatment, filter, wash and dry to obtain pre-modified silica. B3. Add the pre-modified attapulgite clay obtained in step B1 to KH550, stir evenly, then add it to phenolic resin, stir evenly again, then add the pre-modified silica obtained in step B2, stir evenly, and the modified coating is obtained. In step B1, the mass ratio of attapulgite to sodium hydroxide is 1:0.5~0.9; the high-temperature treatment temperature is 780~800℃, and the treatment time is 0.5~4h.

2. The method for preparing a deep-textured decorative panel according to claim 1, characterized in that, Both the first and second decorative panels are made of red cherry wood.

3. The method for preparing a deep-textured decorative panel according to claim 1, characterized in that, In step S1, the adhesive is a polyurethane adhesive, and the application amount on both the upper and lower surfaces is 100~150 g / m². 2 The pressure plate is at room temperature, the pressure is 0.9~1.25MPa, and the time is 4~8h.

4. The method for preparing a deep-textured decorative panel according to claim 1, characterized in that, In step S2, the adhesive is melamine-modified urea-formaldehyde resin; the coating amount on both the upper and lower surfaces is 90~120 g / m². 2 The temperature of the pressure plate is 90~110℃, the pressure is 0.8~1MPa, and the time is 30~60s.

5. The method for preparing a deep-textured decorative panel according to claim 1, characterized in that, In step A2, the mass ratio of magnesium sulfate, magnesium oxide, water, modified fly ash, mullite, and chitosan is 1.5~4:5.5~8:10:55~75:4~8:5~10.

6. The method for preparing a deep-textured decorative panel according to claim 1, characterized in that, In step B2, the volume ratio of hydrogen peroxide to concentrated sulfuric acid is 1:1, the mass concentration of hydrogen peroxide is 26-30%, and the volume ratio of silicon dioxide to the mixed solution is 1g:8-15mL. In step B3, the mass ratio of pre-modified attapulgite, KH550, phenolic resin, and pre-modified silica is 10~15:0.5~1:65:4~7.

7. The deep-textured decorative panel prepared by the method according to any one of claims 1 to 6.

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