High-stability composite floor and processing method thereof

Abstract

The high-stability composite floor comprises a core layer, an ultraviolet curing bonding layer, a decorative layer and a wear-resistant layer. A processing method of a high-stability composite floor comprises the following steps: firstly, providing a core layer, and arranging an ultraviolet curing adhesive layer to be reinforced on the top surface of the core layer; providing a decoration layer to be reinforced, thermally curing the decoration layer to be reinforced, and arranging the thermally cured decoration layer on the top surface of the ultraviolet curing adhesive layer; a wear-resistant layer to be reinforced is arranged on the top surface of the decorative layer; curing the ultraviolet curing adhesive layer to be reinforced, wherein at least one wavelength is longer than the cutoff wavelength of the wear-resistant layer; the ultraviolet curing adhesive layer to be reinforced is irradiated through ultraviolet curing equipment to be cured; the wear-resistant layer to be reinforced is irradiated through ultraviolet curing equipment to be cured, and the wavelength of ultraviolet rays irradiating the ultraviolet curing adhesive layer is longer than the cutoff wavelength of the ultraviolet rays irradiating the wear-resistant layer.

Description

Technical Field

[0001] The invention belongs to the technical field of flooring, in particular to a high-stability composite flooring and a processing method thereof. Background Art

[0002] The technical challenges faced by decorative panels come from multiple root causes that affect their adhesion, durability, aesthetics and overall performance. Delamination is a major issue caused by material incompatibility, where differences in thermal expansion coefficients, polarity or chemical composition can lead to weakened interlayer adhesion. Inconsistent curing can exacerbate this problem, as different cure rates between the adhesive and wear layers can cause residual stresses, while incomplete UV curing can easily cause uncured areas to separate. In addition, moisture absorption by the core and adhesive layers can cause expansion, further weakening the bonding effect. Improper surface preparation (such as insufficient surface energy or contamination) can also reduce the bond strength at critical interfaces. Summary of the invention

[0003] In view of this, the present invention provides a high-stability composite floor with improved bonding effect and a processing method thereof to meet industrial needs.

[0004] A high-stability composite floor comprises at least one core layer, at least one UV-curing adhesive layer coated on the top surface of at least one core layer, a decorative layer arranged on the top surface of the UV-curing adhesive layer, and a wear-resistant layer arranged on the top surface of the decorative layer.

[0005] A method for processing a high-stability composite floor, characterized in that it comprises the following steps:

[0006] Step S100: providing a core layer, and disposing a UV curable adhesive layer to be reinforced on the top surface of the core layer;

[0007] Step S110: providing a decorative layer to be reinforced, thermally curing the decorative layer to be reinforced, and placing the thermally cured decorative layer on the top surface of the ultraviolet curing adhesive layer;

[0008] Step S120: providing a wear-resistant layer to be reinforced on the top surface of the decorative layer;

[0009] Step S130: curing the UV curable adhesive layer to be reinforced, at least one wavelength is longer than the cut-off wavelength of the wear-resistant layer;

[0010] Step S140: curing the UV curable adhesive layer to be reinforced by irradiating the UV curable adhesive layer with a UV curing device;

[0011] Step S150: The wear-resistant layer to be reinforced is cured by ultraviolet curing equipment, wherein the wavelength of ultraviolet rays used to cure the adhesive layer is longer than the cut-off wavelength of ultraviolet rays used to cure the wear-resistant layer.

[0012] Furthermore, the UV curable adhesive layer comprises acrylic acid-polyurethane copolymer, thermosetting resin, and thermosetting resin, wherein the weight percentage of acrylic acid-polyurethane copolymer is 60-80, the weight percentage of thermosetting resin is 10-20, and the weight percentage of photoinitiator is 2-5.

[0013] Furthermore, the decorative layer is made of melamine resin.

[0014] Furthermore, the wear-resistant layer comprises polyurethane acrylate, filler, and ultraviolet absorber; the cutoff wavelength of ultraviolet rays of the wear-resistant layer is 300-350 nm, and the duration of the ultraviolet curing wavelength is 5-10 seconds.

[0015] Furthermore, the UV curing wavelength of the UV curing adhesive layer is 300-450 nm, and the duration of the UV curing wavelength is 10-20 seconds.

[0016] Furthermore, the decorative layer includes melamine resin, and when the decorative layer is thermally cured, the heating temperature is 120-140° C. and the heating time is 10-15 minutes.

[0017] Compared with the prior art, the high-stability composite floor provided by the present invention provides a core layer, and a UV-curable adhesive layer to be reinforced is arranged on the top surface of the core layer, a decorative layer to be reinforced is provided, the decorative layer to be reinforced is thermally cured, and the thermally cured decorative layer is arranged on the top surface of the UV-curable adhesive layer, a wear-resistant layer to be reinforced is arranged on the top surface of the decorative layer, the UV-curable adhesive layer to be reinforced is cured, at least one wavelength is longer than the cut-off wavelength of the wear-resistant layer, the UV-curable adhesive layer to be reinforced is cured by irradiating the UV-curable adhesive layer to be reinforced by an UV-curing device, the wear-resistant layer to be reinforced is cured by irradiating the UV-curable adhesive layer by an UV-curing device, the UV-curable wavelength of the UV-curable adhesive layer is longer than the cut-off wavelength of the UV-curable adhesive layer, that is, the UV-curable adhesive layer and the wear-resistant layer are cured under different UV wavelengths. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 This is a schematic structural diagram of the high-stability composite floor provided by the present invention.

[0019] Figure 2 for Figure 1 Schematic diagram of the process of processing a high-stability composite floor. DETAILED DESCRIPTION

[0020] The specific embodiments of the present invention are further described in detail below. It should be understood that the description of the embodiments of the present invention herein is not intended to limit the protection scope of the present invention.

[0021] like Figure 1 As shown, it is a schematic diagram of the structure of the high-stability composite floor provided by the present invention. The high-stability composite floor comprises at least one core layer 10, at least one UV-curable adhesive layer 20 coated on the top surface of at least one core layer 10, a decorative layer 30 disposed on the UV-curable adhesive layer 20, and a wear-resistant layer 40 disposed on the decorative layer 30. The high-stability composite floor also includes some other functional modules, such as assembly components, etc., which should be well known to those skilled in the art and will not be described in detail one by one here.

[0022] like Figure 2 As shown, it is a schematic diagram of the process structure of the high-stability composite floor provided by the present invention. A processing method of a high-stability composite floor is characterized by comprising the following steps:

[0023] Step S100: providing a core layer, and disposing a UV curable adhesive layer to be reinforced on the top surface of the core layer;

[0024] Step S110: providing a decorative layer to be reinforced, thermally curing the decorative layer to be reinforced, and placing the thermally cured decorative layer on the top surface of the ultraviolet curing adhesive layer;

[0025] Step S120: providing a wear-resistant layer to be reinforced on the top surface of the decorative layer;

[0026] Step S130: curing the UV curable adhesive layer to be reinforced by irradiating the UV curable adhesive layer with a UV curing device;

[0027] Step S140: curing the wear-resistant layer to be reinforced by irradiating it with an ultraviolet curing device, wherein the wavelength of ultraviolet rays irradiating the ultraviolet curing adhesive layer is longer than the cut-off wavelength of ultraviolet rays irradiating the wear-resistant layer, and the wear-resistant layer must be transparent under the cut-off wavelength of ultraviolet rays;

[0028] In step S100, the UV curable adhesive layer includes an acrylic acid-polyurethane copolymer, a thermosetting resin, and a thermosetting resin, wherein the weight percentage of the acrylic acid-polyurethane copolymer is 60-80, and the acrylic acid-polyurethane copolymer is a material prepared by chemical modification or physical blending, which combines the advantages of polyurethane and acrylic acid. The acrylic acid-polyurethane copolymer is a prior art and will not be described in detail here. The UV curable adhesive layer has an ultraviolet curing wavelength of 300-450nm, and the duration of the ultraviolet curing wavelength is 10-20 seconds.

[0029] The weight percentage of thermosetting resin is 10-20. Thermosetting resin is a polymer material that can be cured or has insoluble (melting) characteristics under heating or other conditions. They undergo chemical changes after heating and gradually harden into shape. They do not soften or melt when heated again. The thermosetting resin is a prior art and will not be described here.

[0030] The weight percentage of the photoinitiator is 2-5, wherein in this embodiment, the photoinitiator is an acylphosphine oxide derivative, and the photoinitiator can react with long-wave ultraviolet rays to achieve efficient curing of the ultraviolet curing adhesive layer. The photoinitiator is a prior art and will not be described in detail here.

[0031] The UV-curable adhesive layer has a lower glass transition temperature (Tg), which can reduce the difference in expansion coefficient between layers.

[0032] The wear-resistant layer in step S120 includes polyurethane acrylate, filler, and ultraviolet absorber. The ultraviolet absorber in the wear-resistant layer can prevent the adhesion from decreasing and fading. Polyurethane acrylate is a polymer material that combines the advantages of polyurethane resin and acrylate resin. The ultraviolet absorber is a light stabilizer, which mainly absorbs the ultraviolet part in sunlight and fluorescent light sources without changing itself. The ultraviolet absorber in the wear-resistant layer can prevent the adhesion of the ultraviolet curing adhesive layer from decreasing and fading. The cutoff wavelength of ultraviolet rays in the wear-resistant layer is 300-350nm, and the ultraviolet curing wavelength duration is 5-10 seconds.

[0033] In step S110, the decorative layer is made of melamine resin, which is also called melamine formaldehyde resin. It is a thermosetting resin synthesized by melamine and formaldehyde through addition reaction and dehydration polycondensation reaction. Melamine resin is a prior art and will not be described here. The decorative layer includes melamine resin. When the decorative layer is thermally cured, the heating temperature is 120-140° C. and the heating time is 10-15 minutes.

[0034] like Figure 2 , which is a schematic diagram of the structure of a high-stability composite floor made by the high-stability composite floor processing method provided by the present invention. The high-stability composite floor comprises at least one core layer 10, at least one UV curing adhesive layer 20 coated on the top surface of at least one core layer 10, a decorative layer 30 disposed on the top surface of the UV curing adhesive layer 20, and a wear-resistant layer 40 disposed on the top surface of the decorative layer 30.

[0035] Compared with the prior art, the processing method of the high-stability composite floor provided by the present invention comprises the following steps: providing a core layer, and arranging a UV-curable adhesive layer to be reinforced on the top surface of the core layer; providing a decorative layer to be reinforced, thermally curing the decorative layer to be reinforced, and arranging the thermally cured decorative layer on the top surface of the UV-curable adhesive layer; arranging a wear-resistant layer to be reinforced on the top surface of the decorative layer; curing the UV-curable adhesive layer to be reinforced, at least one wavelength being longer than the cut-off wavelength of the wear-resistant layer; irradiating the UV-curable adhesive layer to be reinforced with a UV curing device to cure it; irradiating the wear-resistant layer to be reinforced with a UV curing device to cure it, and the wavelength of the UV rays irradiating the UV-curable adhesive layer is longer than the cut-off wavelength of the UV rays irradiating the wear-resistant layer, that is, the UV-curable adhesive layer and the wear-resistant layer are cured under different UV wavelengths.

[0036] The above are only preferred embodiments of the present invention and are not intended to limit the protection scope of the present invention. Any modification, equivalent substitution or improvement within the spirit of the present invention is included in the scope of the claims of the present invention.

Claims

1. A high stability composite floor, characterized in that: The high-stability composite floor comprises at least one core layer, at least one UV-curable adhesive layer coated on the top surface of at least one core layer, a decorative layer arranged on the top surface of the UV-curable adhesive layer, and a wear-resistant layer arranged on the top surface of the decorative layer.

2. A method for processing a high-stability composite floor, characterized in that: The following steps are involved: Step S100: providing a core layer, and disposing a UV curable adhesive layer to be reinforced on the top surface of the core layer; Step S110: providing a decorative layer to be reinforced, thermally curing the decorative layer to be reinforced, and placing the thermally cured decorative layer on the top surface of the ultraviolet curing adhesive layer; Step S120: providing a wear-resistant layer to be reinforced on the top surface of the decorative layer; Step S130: curing the UV curable adhesive layer to be reinforced, at least one wavelength is longer than the cut-off wavelength of the wear-resistant layer; Step S140: curing the UV curable adhesive layer to be reinforced by irradiating the UV curable adhesive layer with a UV curing device; Step S150: The wear-resistant layer to be reinforced is cured by ultraviolet curing equipment, wherein the wavelength of ultraviolet rays used to cure the adhesive layer is longer than the cut-off wavelength of ultraviolet rays used to cure the wear-resistant layer.

3. The high stability composite floor as claimed in claim 1, characterized in that: The ultraviolet curable adhesive layer comprises acrylic acid-polyurethane copolymer, thermosetting resin, and thermosetting resin, wherein the weight percentage of acrylic acid-polyurethane copolymer is 60-80, the weight percentage of thermosetting resin is 10-20, and the weight percentage of photoinitiator is 2-5.

4. The high stability composite floor as claimed in claim 1, characterized in that: The decorative layer is made of melamine resin.

5. The high stability composite floor as claimed in claim 1, characterized in that: The wear-resistant layer comprises polyurethane acrylate, filler and ultraviolet absorber. The ultraviolet cut-off wavelength of the wear-resistant layer is 300-350nm, and the ultraviolet curing wavelength duration is 5-10 seconds.

6. The high stability composite floor as claimed in claim 1, characterized in that: The ultraviolet curing wavelength of the ultraviolet curing adhesive layer is 300-450nm, and the duration of the ultraviolet curing wavelength is 10-20 seconds.

7. The high stability composite floor as claimed in claim 1, characterized in that: The decorative layer comprises melamine resin. When the decorative layer is thermally cured, the heating temperature is 120-140° C. and the heating time is 10-15 minutes.

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