Plate with 3D texture structure, preparation method and application

Abstract

The invention belongs to the technical field of decorative plates, and particularly relates to a plate with a 3D texture structure and a preparation method and application thereof.The plate at least comprises a base material, a pattern layer, a wear-resistant layer and a finish paint layer from bottom to top; the wear-resistant layer comprises a thickness adjusting layer and a texture layer located on the thickness adjusting layer, the texture layer comprises a base part and a three-dimensional part, the three-dimensional part is located above the base part, the pattern layer comprises a plurality of connected or disconnected wood-grain-shaped lines, the three-dimensional part comprises a plurality of connected or disconnected wood-grain-shaped grooves, and the thickness adjusting layer is located above the thickness adjusting layer. At least part of the grooves correspond to the lines in one or more of the arrangement position, the length or the width, and at least part of the top of the finish paint layer is lower than the upper surface of the three-dimensional part. The plate provided by the invention provides excellent wear resistance, and meanwhile, the formed 3D texture is better in definition and better in touch hand feeling and visual effect.

Description

[0001] This invention is a divisional of a patent for invention with the application date of "March 31, 2023", the invention title of "A board with a 3D texture structure, preparation method and application", and the application number of "202310337404.9". Technical Field

[0002] This invention belongs to the technical field of decorative boards, and particularly relates to a board with a 3D texture structure, a preparation method and an application. Background Art

[0003] In the decorative board industry, to form a pattern structure with a 3D texture effect on the surface of a substrate, it is currently mainly achieved through the following two methods.

[0004] First, a raised three-dimensional effect is created by printing and stacking on a flat coating.

[0005] Related prior art, for example, CN109653465A discloses a 3D effect PVC decorative board and its 3D printing production method. The PVC decorative board includes a PVC board substrate, and successively from bottom to top, there are also a UV primer layer, a UV white paint layer, a pattern layer, a UV wear-resistant paint layer, a concave-convex effect layer, and a UV topcoat layer. The UV white paint layer has 2 layers, the UV wear-resistant paint layer has 3 layers, and the UV topcoat layer has 2 layers. Among them, the concave-convex effect layer is formed by printing the concave-convex effect layer on the cured UV wear-resistant paint layer through a flatbed inkjet printer. At this time, the concave-convex effect layer is UV transparent paint, and then according to the pattern of the pattern layer, spray paint is stacked at specific graphic positions; thus, a concave-convex effect layer with a specific pattern is formed.

[0006] The effect stacked in this way is relatively rigid, and since the edges of the formed wood grain are obtuse angles, it is difficult to imitate the effect of real wood grain both visually and tactilely. The concave-convex effect layer formed by stacking has a poor foot feeling comfort when used on the floor.

[0007] Second, a concave texture effect is made by removing the corresponding part of the texture by wire drawing on a flat coating.

[0008] The related prior art is introduced as follows.

[0009] CN112739463A discloses a method and device for generating a surface structure, including the following steps: A) applying resin A to the surface of a material; B) when the resin A is liquid or partially cured, applying liquid B to at least a part of the resin A; C) polymerizing the resin A and the liquid B respectively; D) removing the polymerized liquid B, thereby generating a three-dimensional structure.

[0010] This patent application discloses the principle of using a concave method to form a texture, and analyzes the physical and chemical properties of liquid B and resin A as embossing liquid to screen out a suitable liquid B. However, there is no special description of the performance requirements for the final product with a three-dimensional structure.

[0011] CN110773403A discloses a 3D printing plate with a brushed surface effect, the structure of which is a base layer, a UV primer layer, a UV white paint layer, a UV transition paint layer, a color pattern layer, a UV wear-resistant paint, a 3D texture layer, and a UV topcoat layer from bottom to top. A flatbed inkjet printer is used to spray varnish on the uncured UV wear-resistant paint surface, and the position of the varnish corresponds to the pattern texture position of the color pattern layer; after printing is completed, the LED provided by the printer is used for drying and curing; at this time, the cured part is limited to the part not covered by the varnish, and the wear-resistant paint of the part covered by the varnish is not cured; then a wood grain drawing machine is used to draw the uncured printed parts in the 3D texture, so as to obtain a 3D texture layer.

[0012] In this patent application, varnish is printed on the uncured wear-resistant paint, and the varnish is used to cover part of the wear-resistant paint so that it will not be cured in the subsequent curing process, so that it can be removed to form grooves. Since the uncured part of the wear-resistant paint in the area blocked by the varnish is regular, the grooves formed in this way are quite different from the real wood grain in terms of both visual effect and touch. Moreover, from the patent application Figure 1 From the looks of it, the surface of the formed board is flat, and there is no focus on the three-dimensional feel of the touch.

[0013] In summary, although the second method has a greater advantage than the first method in that the three-dimensional texture obtained is closer to the real wood grain, the second method is still in its early stages and there are still many problems to be solved. For example, the wear-resistant layer is in a semi-cured or uncured form, and the texture layer is formed by drawing on these wear-resistant layers, which destroys the wear-resistant layer structure, reduces the wear resistance of the board, and even destroys the pattern of the pattern layer; for another example, the 3D structure formed has a poor three-dimensional effect, the texture is not natural enough, and especially the clarity is poor. Summary of the invention

[0014] In order to solve the above-mentioned defects existing in forming 3D texture on the existing substrate, the present invention provides a plate having a 3D texture structure.

[0015] The plate with a 3D texture structure provided by the present invention has a better 3D texture forming effect and visual effect while ensuring the wear resistance of the plate by improving the substrate for forming the 3D texture.

[0016] The scheme adopted by the present invention is as follows: A board with a 3D texture structure includes at least a base material, a pattern layer, a wear-resistant layer, and a topcoat layer from bottom to top; the wear-resistant layer includes a thickness adjustment layer and a texture layer located above the thickness adjustment layer, the texture layer includes a base part and a three-dimensional part, the three-dimensional part is located above the base part, the pattern layer contains several connected or unconnected lines in the shape of wood grains, the three-dimensional part includes several connected or unconnected grooves in the shape of wood grains, at least part of the grooves correspond to the lines in one or more of the arrangement position, length, or width, and the top of at least part of the topcoat layer is lower than the upper surface of the three-dimensional part.

[0017] Currently, the 3D digital printing boards are mostly in the theoretical research and development stage, and there are relatively few 3D digital printing boards in the market. By comparing the existing boards with 2D printed boards in terms of vision and touch, it is found that the clarity of 3D digital printing boards is significantly insufficient, the patterns are blurred, and the three-dimensional feeling of touch is also relatively weak. The inventor of the present invention analyzed these defects in order to solve them.

[0018] In the 3D digital printing boards in the prior art, a three-dimensional structure is formed on the uncured wear-resistant layer above the pattern layer. Since the pattern layer is not protected, the pattern layer is extremely easy to be damaged during the wire drawing process or the later use process, that is, the wear resistance is poor. For example, in the 3D printing board disclosed in CN110773403A mentioned in the background art, wire drawing grooves are formed on the uncured wear-resistant layer covered with varnish. Whether the pattern on the pattern layer will be damaged during the wire drawing process depends on the depth of the 3D texture. If a deeper 3D texture is required and the depth penetrates the thickness of the wear-resistant layer, there is still the problem of damage to the pattern layer mentioned above.

[0019] In addition, compared with 2D printed boards, since 3D printing boards need to form a 3D texture, a 3D texture is formed above the pattern layer through a wear-resistant layer, and then multiple layers such as a topcoat layer are coated on it, resulting in a decrease in the pattern clarity of the formed board.

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

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

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

[0023] The texture layer in the present invention is used as a 3D texture structure forming part, and a groove structure is formed on it to form a three-dimensional part of the texture layer. However, on the texture layer, the groove does not penetrate, and a base part is reserved below the three-dimensional part, and no groove is formed on the base part. After the wear-resistant layer is set as the thickness adjustment layer and the texture layer, there must be a problem of connection strength, and it is also found in actual use that the formed plate is easy to film and fall off on the surface after a period of use. The texture layer is provided with a base part, and there is a certain distance (the thickness of the base part) between the bottom of the groove and the thickness adjustment layer. The groove will not penetrate the thickness direction of the texture layer, ensuring the integrity of the contact surface between the thickness adjustment layer and the texture layer, which is conducive to ensuring the connection strength between the thickness adjustment layer and the texture layer. Moreover, if there is no base part, the thickness adjustment layer is very easy to be scratched in the process of forming the groove, and the scratched part will affect the visual effect and clarity of the pattern. Therefore, compared with the wear-resistant layer without a base part, the 3D texture formed by the present invention has better clarity and better visual effect. Moreover, the inventors found that before applying the wear-resistant layer forming the 3D texture, a cured thickness adjustment layer is formed on the pattern layer, which can appropriately increase the thickness of the three-dimensional part of the texture layer without affecting the clarity of the pattern, and still have ideal clarity. Using a thicker three-dimensional part can achieve a 3D texture with deeper lines, and even after covering the topcoat layer, it still has a clear sense of concave and convex, and the touch is closer to the natural effect. For example, the texture layer usually reaches 100g / m 2 After forming a cured thickness adjustment layer on the pattern layer, the texture layer can reach 150g / m 2 And above, it still has ideal clarity.

[0024] The texture layer of the present invention has different thicknesses, and the clarity of the pattern will be affected. In this case, the clarity can be adjusted by adjusting the coating thickness of the thickness adjustment layer.

[0025] In some specific embodiments, the bottom and / or inner wall of the groove has a number of protrusions. The protrusions can be regular or irregular. On the one hand, the protrusions are beneficial to improving the adhesion of the topcoat, so as to improve the surface performance of the board. On the other hand, due to the existence of the protrusions, the touch feeling of the board is more real.

[0026] In some specific embodiments, the number of protrusions on the bottom of at least part of the groove exceeds the number of protrusions on the side wall, and / or the area of the protrusions on the bottom is larger than the area of the protrusions on the side wall.

[0027] In some specific embodiments, the protrusions account for at least 1%, or at least 5%, or at least 10%, or at least 15%, or at least 20%, or at least 25%, or at least 30%, or at least 35%, or at least 40%, or at least 45% of the total inner surface area of the groove, but generally do not exceed 50%.

[0028] In some specific embodiments, the side wall and the bottom of at least part of the groove are connected at an obtuse angle. For the groove connected at an obtuse angle, when touched, it is closer to the touch feeling of real wood grain and has better comfort.

[0029] In some specific embodiments, the side wall has a raised and / or sunken area to enrich the touch feeling.

[0030] In some specific embodiments, the depth of the groove is 0.03 mm to 0.20 mm, and more preferably 0.08 mm to 0.20 mm.

[0031] In some specific embodiments, at least part of the groove includes a hand feeling deepening part in the middle, a visual simulation part at both ends, and a transition part between the hand feeling deepening part and the visual simulation part. The width of at least part of the visual simulation part is smaller than the width of the hand feeling deepening part.

[0032] In some more preferred embodiments, the depth of the visual simulation part of at least part of the groove is smaller than the depth of the hand feeling deepening part.

[0033] In the above technical solution, the groove is divided into three parts, and the main functions of different parts are different. The hand feeling deepening part provides a more obvious three-dimensional touch feeling; the visual simulation part, in cooperation with the hand feeling deepening part, provides a touch feeling closer to real wood grain, and the visual simulation part can also improve the visual effect, making the board look more like real wood grain; the transition part mainly plays a connecting role between the previous two parts. By controlling the different depths and widths of each part, the 3D texture effect of the board is realized as a whole, and it is closer to the real wood texture visually and tactilely.

[0034] In some specific embodiments, the thickness of the thickness adjustment layer may be the same as or different from the thickness of the texture layer.

[0035] In some other preferred embodiments, the thickness of the texture layer is greater than the thickness of the thickness adjustment layer. The thickness of the two parts is determined according to their functions. The texture layer is used to form a groove structure and requires a greater thickness to form deeper grooves to achieve a more three-dimensional 3D effect.

[0036] The wear-resistant layer is formed by coating with wear-resistant paint. The composition of the wear-resistant paint usually includes photosensitive resin, photoinitiator and other additives. The other additives can be one or a combination of more of curing agent, catalyst, crosslinking agent, leveling agent, antioxidant, defoaming agent, inorganic filler, pigment, plasticizer, etc.

[0037] In some specific embodiments, the photosensitive resin is one or a combination of more of resins such as epoxy resin, acrylic resin, acrylic modified polyurethane resin, acrylic modified silicone resin, acrylic modified epoxy resin, etc.

[0038] In some specific embodiments, the material of the thickness adjustment layer may be the same as or different from the material of the texture layer.

[0039] In some other embodiments, the material of the thickness adjustment layer is different from the material of the texture layer. The main functions of the thickness adjustment layer and the texture layer are different, and the materials are selected according to their respective functional requirements, which is more beneficial to the functions of different forms of wear-resistant layers.

[0040] In some specific embodiments, the coating amount of the wear-resistant paint used for the thickness adjustment layer is 35 g / m 2 to 55 g / m 2 .

[0041] In some specific embodiments, the coating amount of the wear-resistant paint used for the texture layer is greater than or equal to 150 g / m 2 .

[0042] In some specific embodiments, the texture layer is formed by two coatings with opposite coating directions. The coating amount of the wear-resistant paint used for the first coating is greater than or equal to 75 g / m 2 , and the coating amount of the wear-resistant paint used for the second coating is greater than or equal to 75 g / m 2 .

[0043] The texture layer often needs to be thicker to form deeper grooves to highlight the concave and convex feeling of touch. The inventors of the present invention found through testing that only when the total coating amount used for the texture layer is greater than 150 g / m 2and above can the texture formed reach an approximate natural wood feel. When coated at one time with 150 g / m 2 above, not only will the processing difficulty increase, but also the roller coating will be uneven, resulting in uneven internal structure and thickness of the texture layer, thus affecting the overall clarity. In this solution, the texture layer is formed by two coatings, and the roller coating directions are opposite, so that when implementing the second coating, a force opposite to the internal stress inside can be provided to the uncured second layer, thereby weakening or offsetting the original internal stress in the texture layer, and thus being able to avoid cracking in the middle of the cured texture layer and overcoming the defect of poor clarity caused by internal cracking.

[0044] The substrate can be plate materials of different properties, including wood and wood-derived products, such as SPC stone plastic plates, etc. Select the material of the substrate according to specific applications.

[0045] The thickness of the substrate layer can be determined according to specific applications. For example, in the case of a decorative panel for furniture, it is usually between 5 mm and 25 mm, while the thickness for producing floors is between 2 mm and 6 mm.

[0046] In some specific embodiments, the above-mentioned plate also includes a white film, which is formed on the substrate in any way, such as using a PVC white film, attached to the substrate, for adjusting the background color of the substrate to highlight the clarity of the printed pattern in the subsequent pattern layer.

[0047] In some specific embodiments, the above-mentioned plate also includes a primer layer, which is coated on the white film to provide good adhesion for the subsequent coatings.

[0048] In some specific embodiments, the above-mentioned plate also includes a color paint layer, which is located between the primer layer and the pattern layer.

[0049] In some specific embodiments, the color paint layer is formed after roller or spraying color paint on the cured primer and then curing. The color of the color paint is determined according to the requirements of the printed pattern, generally white, and other colors can also be selected according to the requirements of the printed pattern. This layer corrects the background color of the substrate on the one hand and can also adjust the polarity of the surface to be printed on the substrate to improve the adhesion of the pattern layer on the other hand. The curing of the primer layer, pattern layer, color paint layer, and wear-resistant layer can be photo-curing, thermal curing, or electron beam curing. Photo-curing includes, for example, UV lamps, mercury lamps, LED lamps, potassium lamps, etc. Especially using LED lamps for curing has little light pollution.

[0050] In some specific embodiments, the pattern layer is photo-cured after printing patterns with a multi-color ink digital printer on the primer layer, and various patterns such as wood grain, stone grain, or personalized customized patterns can be printed.

[0051] The curing of the pattern layer can be photocuring, thermal curing or electron beam curing. Photocuring examples include UV lamps, mercury lamps, LED lamps, potassium lamps, etc. In particular, LED lamps are used for curing, with less light pollution.

[0052] In some specific embodiments, the pattern layer and the texture layer are formed by digital printing. The digital printing ink can be UV ink, weak solvent ink, water-based ink, oil-based ink, etc.

[0053] The topcoat layer is formed by coating a topcoat on the wear-resistant layer and then curing.

[0054] The topcoat layer can be one layer or multiple layers, mainly giving the board a bright and matte effect and improving the gloss of the board surface. The topcoat layer can also endow the board with some other functions, such as stain resistance, mildew resistance, antibacterial, waterproof, fireproof, crack resistance, anti-slip, negative ion, formaldehyde removal, wear resistance functions.

[0055] The present invention also provides a method for preparing the above board with a 3D texture structure, including the following steps: S1. Coating a color paint on the substrate, curing to form a color paint layer; S2. Printing a wood grain pattern on the color paint layer to form a pattern layer; S3. Coating a wear-resistant paint on the pattern layer, curing to form a thickness adjustment layer of the wear-resistant layer; S4. Coating a wear-resistant paint on the thickness adjustment layer of the wear-resistant layer without curing to form a texture layer; S6. Applying an embossing liquid on the surface of at least a part of the texture layer; S7. Curing the texture layer, removing the uncured or incompletely cured part, thereby forming grooves on the texture layer; S8. Coating a topcoat on the surface obtained in S7, curing to form a topcoat layer, thus obtaining a board with a 3D texture structure.

[0056] In the above preparation method, the creative steps are steps S3 and S7.

[0057] In step S3 of the present invention, when forming the wear-resistant layer, first coat and cure to form a thickness adjustment layer, that is, before coating the texture layer, the thickness adjustment layer undergoes a curing process for curing.

[0058] The board formed by this method has at least the following advantages: Protect the pattern layer: The thickness adjustment layer has been cured before forming the grooves, and the thickness adjustment layer does not form a groove structure. This thickness adjustment layer protects the pattern layer from being damaged during the process of forming the grooves.

[0059] It has better wear resistance: the thickness adjustment layer is a complete layer, which can provide excellent wear resistance and ensure the wear resistance of the plate to resist the friction of the external force on the plate during use.

[0060] Providing higher clarity: This is also an unexpected effect of the plate made by this method. After adding an extra layer (thickness adjustment layer), the 3D texture formed by the present invention has better clarity and better visual effect than the wear-resistant layer without a thickness adjustment layer. The reason for this may be: In the prior art, the texture layer is directly coated on the pattern layer to form a texture layer. During the curing process of the texture layer, the energy used for curing the wear-resistant paint is usually input from the top of the texture layer. The wear-resistant paint on the top will be cured first, and the wear-resistant paint on the bottom will be cured later. Since the wear-resistant paint is often accompanied by a certain volume shrinkage during the curing process, a certain internal stress will be generated. These internal stresses will be superimposed downward, thereby reaching a maximum value at the bottom of the resin liquid. If the wear-resistant paint is in direct contact with the pattern layer at this time, once the maximum internal stress is greater than the bonding force between the pattern layer and the next layer, it will cause slippage between the pattern layer and the surface of the plate, which will cause the pattern layer at the bottom to be difficult to correspond to the groove, resulting in visual blur and a significant reduction in clarity. In the present invention, a thickness adjustment layer with a smaller thickness is first formed on the pattern layer. The internal stress generated by the thickness adjustment layer after solidification is relatively weak, and will not exert excessive force on the pattern layer, thereby ensuring the accuracy of the wood grain position of the pattern layer. On the other hand, in the prior art, the texture layer is directly coated on the pattern layer. Since the wood grain pattern on the pattern layer is discontinuous, the wear-resistant paint is coated on the discontinuous wood grain pattern. Due to the influence of the wood grain pattern, the consistency of the shrinkage of the wear-resistant paint during solidification is affected, resulting in uneven internal shrinkage of the texture layer after solidification, and the appearance of fine lines, thereby causing a decrease in clarity. The surface of the thickness texture layer of the present invention is smooth, and the wear-resistant paint of the texture layer has consistent shrinkage when solidified on the surface, and no fine lines will appear inside the texture layer, resulting in good clarity.

[0061] Another function of the thickness adjustment layer is that the clarity of the plate can be improved by adjusting its thickness. The texture layer is used as a part of the 3D texture structure, and the groove structure formed on it will not affect the wear resistance of the plate. Moreover, compared with the wear-resistant layer without the thickness adjustment layer, the 3D texture formed by the present invention has better clarity and better visual effect.

[0062] Achieve a deeper 3D texture: This method can also appropriately increase the thickness of the texture layer without affecting the clarity of the pattern, and still have ideal clarity. Using a thicker texture layer can achieve a deeper 3D texture, even after covering the topcoat layer, it has a clear sense of concave and convex, and the touch is closer to the natural effect.

[0063] When forming the grooves of the texture layer in the S7 of the present invention, a base part is reserved. The formation of the base part is based on the thickness difference between the texture layer and the depth of the grooves. Reserving the base part has at least the following advantages: Enhance the connection force between the texture layer and the thickness adjustment layer: A base part is set in the texture layer. There is a certain distance (the thickness of the base part) between the bottom of the groove and the thickness adjustment layer. The groove does not penetrate the thickness direction of the texture layer, ensuring the integrity of the contact surface between the thickness adjustment layer and the texture layer, which is beneficial to ensuring the connection strength between the thickness adjustment layer and the texture layer.

[0064] Improve clarity: If there is no base part, during the formation of the groove, the thickness adjustment layer is extremely easy to be scratched, and the scratched part will affect the visual effect and clarity of the pattern. Therefore, compared with the wear-resistant layer without the base part, the 3D texture formed by the present invention has better clarity and better visual effect. The texture layer formed by the above method has grooves in the upper part, which are three-dimensional parts. A base part is reserved below the three-dimensional part, and no grooves are formed on the base part. The three-dimensional part and the base part are integrally connected and belong to different parts of the texture layer.

[0065] In some specific embodiments, the coating amount of the wear-resistant paint used for the thickness adjustment layer is 35 g / m 2 to 55 g / m 2 .

[0066] In some specific embodiments, the coating amount of the wear-resistant paint used for the texture layer is greater than or equal to 150 g / m 2 .

[0067] In some specific embodiments, the base part and the three-dimensional part of the texture layer are formed by two coatings. The coating amount of the wear-resistant paint used for the base part is greater than or equal to 75 g / m 2 , and the coating amount of the wear-resistant paint used for the three-dimensional part is greater than or equal to 75 g / m 2 .

[0068] In some specific embodiments, the coating direction for forming the base part is opposite to the coating direction for forming the three-dimensional part.

[0069] In some specific embodiments, in step S5, a steel brush is used to remove the uncured or incompletely cured part. Using a steel brush to remove it is easy to form a finer wire drawing texture, and the formed groove has a shape closer to the natural wood texture.

[0070] The present invention adopts a specific preparation method to form a specific board with a 3D texture structure. The pattern presented by the board has excellent clarity, and the presented 3D texture has more excellent three-dimensional sense and touch feel.

[0071] The present invention also provides applications of the above-mentioned board or the board obtained by the above-mentioned preparation method, specifically applications in floors, wall panels or ceiling panels.

[0072] In summary, the present invention has the following advantages: 1. The present invention sets the wear-resistant layer as a thickness adjustment layer and a texture layer. No groove structure is formed in the thickness adjustment layer. The thickness adjustment layer protects the pattern layer from being damaged during the formation of the groove. The thickness adjustment layer also provides excellent wear resistance to ensure the wear resistance of the plate to resist the friction of the plate caused by external forces during use. The texture layer is a part forming the 3D texture structure. Forming the groove structure on it will not affect the wear resistance of the plate. Moreover, compared with the wear-resistant layer without the thickness adjustment layer, the 3D texture formed by the present invention has better clarity and better visual effect.

[0073] 2. The thickness adjustment layer in the present invention can also be used to adjust the clarity of the board. The clarity of the board can be adjusted by changing the thickness of the thickness adjustment layer according to the thickness of the texture layer and the depth of the groove.

[0074] 3. The present invention uses a wear-resistant layer with a thickness adjustment layer, which can appropriately increase the thickness of the texture layer without affecting the clarity of the pattern, and still have ideal clarity. Using a thicker texture layer can achieve a 3D texture with deeper lines, and even after covering the topcoat layer, it still has a clear sense of concave and convex, and the touch is closer to the natural effect.

[0075] 4. The present invention can also use the grooves to increase the connection force between layers and ensure the overall performance of the board. BRIEF DESCRIPTION OF THE DRAWINGS

[0076] Figure 1 A schematic diagram of the hierarchical structure of a plate material provided in Example 1 of this specification; Figure 2 A schematic diagram of a partial three-dimensional structure of a plate provided in Example 1 of this specification; Figure 3 This is an enlarged schematic diagram of a groove of a plate provided in Example 1 of this specification; Figure 4 A schematic diagram of a partial three-dimensional structure of a plate provided in Comparative Example 1 of this specification; Figure 5 A top view of a plate provided for comparative example 1 of this specification; Figure 6 This is an enlarged schematic diagram of a portion of the grooves of the plate provided in Comparative Example 4 of this specification. DETAILED DESCRIPTION

[0077] The technical solution of the present invention will be described in detail below in conjunction with specific embodiments.

[0078] Example 1 A board with a 3D texture structure, as shown in the Figure 1 accompanying drawings, successively includes from bottom to top: a base material 01, a white film 02, a primer layer 03, a color paint layer 04, a pattern layer 05, a wear-resistant layer 06, and a topcoat layer 07.

[0079] In this example, SPC stone plastic wood is used as the base material with a thickness of 4 mm. The white film is a commercially available PVC white film, which is attached to the base material online after the base material is extruded.

[0080] The primer layer is made of transparent acrylic varnish, which is roller-coated on the white film and cured by an ultraviolet lamp.

[0081] The color paint is white paint, which is roller-coated on the primer layer and cured by an ultraviolet lamp.

[0082] The pattern layer is formed by printing patterns with a multi-color ink digital printer and then undergoing light curing. In this example, the printed pattern is a wood grain pattern, and the pattern layer has several connected or unconnected lines in the shape of wood grains.

[0083] The wear-resistant layer includes two layers, a thickness adjustment layer located above the pattern layer and a texture layer located above the thickness adjustment layer. The thickness adjustment layer is formed by coating transparent wear-resistant paint on the pattern layer and undergoing light curing. The curing step has been completed before the texture layer is coated.

[0084] The texture layer of the wear-resistant layer is formed by coating transparent wear-resistant paint on the thickness adjustment layer. In the texture layer, there are several connected or unconnected grooves 06a in the shape of wood grains. For different grooves, the width, depth, and length may be different. The width, depth, and length of the grooves are associated with the patterns of the pattern layer. The grooves correspond to the lines of the pattern layer in terms of layout position, length, or width, and the pattern alignment is accurate.

[0085] The texture layer is formed by coating wear-resistant paint on the thickness adjustment layer, and grooves are formed on the texture layer. The maximum depth of the grooves is less than the thickness of the texture layer. The unpenetrated bottom of the texture layer is the base part, and above the base part is the three-dimensional part with grooves.

[0086] The topcoat layer is made of topcoat, which is coated on the surface of the three-dimensional part of the wear-resistant layer. The top of the topcoat layer corresponding to the grooves is lower than the upper surface of the other three-dimensional parts outside the grooves.

[0087] The board of this example is analyzed by a laser profiler. The results are shown in Figure 2 and Figure 3 .

[0088] From Figure 2It can be clearly seen that the surface of the board provided in this embodiment has an obvious concave-convex structure brought by the grooves. There is an obvious sense of concave and convex when touching it.

[0089] From Figure 3 It can be seen that for some of the grooves, there are raised areas and sunken areas on the side walls of the grooves. There are irregular protrusions 06b on both the bottom and side walls of the grooves. The number of protrusions at the bottom of the grooves is significantly more than that on the side walls. The area of the protrusions accounts for about 10% of the total inner surface area of the grooves. The number of protrusions can be adjusted at least by the diameter and distribution density of the wire brush on the steel roller of the wire drawing machine. For example, by reducing the diameter of the wire brush and increasing the density, the number and area ratio of the protrusions will decrease.

[0090] Looking at the structure of a single groove, some of the grooves generally include three parts: a feel-enhancing area in the middle region, visual simulation parts at both ends, and a transition part between the feel-enhancing part and the visual simulation parts. Among them, the feel-enhancing part is the area with the greatest depth, and some grooves can reach 0.2 mm. For some grooves, the width of the visual simulation parts at both ends is less than the width of the feel-enhancing part, and for some other grooves, the width of the visual simulation part at one end is less than the width of the feel-enhancing part, and the width of the visual simulation part at the other end is equivalent to the width of the feel-enhancing part. The wood grain formed by the grooves with this special structure is closer to the real wood grain in terms of visual effect and touch feel.

[0091] Example 2 This embodiment specifically describes the preparation method of the board with a 3D texture structure in Example 1, which specifically includes the following steps: (S.1) Place the SPC board with a white film attached, having dimensions of 1260 mm * 970 mm * 4.85 mm, on the surface of a conveying device moving in a fixed direction; (S.2) During the conveying process, the SPC board first passes through a first roll coater. The coating roller surface of this roll coater is attached with a photocurable primer (the primer contains: 90% photocurable varnish HYS01-1, 5% photoinitiator 184, 0.5% photoinitiator TPO, 4.5% diluent hydroxyethyl acrylate). During the contact process between the SPC board and the coating roller, 12 g / m 2 of the primer is coated on the surface of the SPC board and cured with a UV lamp of 395 nm and 8 W / cm 2 to form a primer layer; (S.3) The SPC board obtained in the previous step is further passed through a second roll coater. The coating roll surface of this roll coater is attached with a photocurable white paint (the white paint contains: 50% photocurable epoxy HYS01-1, 30% titanium dioxide, 5% photoinitiator 184, 0.5% photoinitiator TPO, 14.5% diluent hydroxyethyl acrylate). During the process of the SPC board contacting the coating roll, 18 g / m 2 of the white paint is coated on the surface of the primer, and after curing with a 395 nm and 8 W / cm 2 UV lamp, a white paint layer is obtained; (S.4) The SPC board obtained in the previous step is conveyed to a first inkjet printer, and 6 - 8 g / m 2 of ink is sprayed on the surface of the paint layer through the first inkjet printer. After the ink is cured, a pattern layer with a wood grain pattern is formed on the surface of the primer layer; (S.5) The SPC board obtained in the previous step is conveyed into a third roll coater, and 45 g / m 2 of a photocurable resin solution (the resin solution contains: 90% Dow Corning 65 Additive, 5% photoinitiator 184, 0.5% photoinitiator TPO, 4.5% diluent hydroxyethyl acrylate) is roll-coated on the surface of the pattern layer. It is successively irradiated and cured by a 395 nm and 8 W / cm 2 UV lamp and a 160 w / cm 2 Hg lamp to form a thickness adjustment layer; (S.6) The SPC board obtained in the previous step is conveyed into a fourth roll coater, and the coating roll of the fourth roll coater rolls 80 g / m 2 of the resin solution (the resin solution contains: 90% Dow Corning 65 Additive, 5% photoinitiator 184, 0.5% photoinitiator TPO, 4.5% diluent hydroxyethyl acrylate) along the conveying direction of the SPC board (the rotation direction of the roll itself is clockwise) on the surface of the thickness adjustment layer, forming the base part of the texture layer; (S.7) After the first layer of resin solution is coated, the SPC board is conveyed forward along the surface of the conveying equipment, and it is ensured that before being conveyed to the next roll coater, the fourth roll coater does not apply any force to the resin solution; (S.8) The SPC board obtained in the previous step is conveyed to a fifth roll coater, and the coating roll of the fifth roll coater continues to roll 75 g / m 2 of the resin solution (the resin solution here is the same as the resin solution in step (S.6)) against the conveying direction of the SPC board (the rotation direction of the roll itself is clockwise), forming the three-dimensional part of the texture layer; (S.9) Convey the SPC board obtained in the previous step to the second inkjet printer, and spray 8 g / m² of embossing liquid (the embossing liquid contains: 45.5% diacrylate monomer PEG600DA, 20.5% p - hydroxyanisole HQMME, 10% 2 - tert - butylhydroquinone MTBHQ, 24% diethylene glycol butyl ether) on the surface of the resin liquid, and allow the embossing liquid to penetrate downward into the resin liquid and mix with the resin liquid; 2 (S.10) Pass the SPC board obtained in the previous step successively through a UV lamp with a wavelength of 395 nm and an intensity of 8 W / cm² and a Hg lamp with an intensity of 160 W / cm² for deep curing; (S.10) Pass the SPC board obtained in the previous step successively through a UV lamp with a wavelength of 395 nm and an intensity of 8 W / cm² and a Hg lamp with an intensity of 160 W / cm² for deep curing; 2 of UV lamp and a Hg lamp with an intensity of 160 W / cm² 2 for deep curing; (S.11) Convey the SPC board obtained in the previous step under a cleaning device containing a steel brush (wire diameter 0.02 mm), so that the part where the embossing liquid is mixed with the resin liquid is brushed out by the steel brush, thereby forming grooves in these parts; (S.12) Pass the SPC board obtained in the previous step through a sixth roll coater to coat 12 g / m² of topcoat, and cure it under a UV lamp with a wavelength of 395 nm and an intensity of 8 W / cm² to obtain a topcoat layer. 2 of topcoat, and cure it under a UV lamp with a wavelength of 395 nm and an intensity of 8 W / cm² 2 to obtain a topcoat layer.

[0092] Comparative Example 1 It is basically the same as the steps of Example 2, except that in Comparative Example 1, step (S.5) is omitted, so the prepared board does not contain a thickness adjustment layer. Figure 4 and Figure 5 are respectively the three - dimensional structure diagram and the top - view structure diagram of the board prepared in Comparative Example 1 of the present disclosure. It can be seen from the figure that after omitting step (S.5), the average depth of the formed wood grain is smaller, and the texture on the surface of the board is quite different from the real wood grain both visually and tactilely.

[0093] Comparative Example 2 It is basically the same as the steps of Example 2, except that in step (S.5) of this comparative example, after roll - coating the wear - resistant paint, no curing treatment is performed. The board obtained in this comparative example has a similar wood grain depth as the board obtained in Example 2, but its clarity and wear resistance are significantly worse.

[0094] Comparative Example 3 It is basically the same as the steps of Example 2, except that after step (S.8), the wear - resistant paint is irradiated with ultraviolet light, so as to obtain an incompletely cured texture layer. The average depth of the formed wood grain is lower and the clarity decreases.

[0095] Comparative Example 4 It is basically the same as the steps of Example 2, except that the amount of the embossing liquid applied in step (S.9) is 15 g / m 2 . The maximum depth of the formed groove is slightly greater than the thickness of the texture layer. At the deepest part, the texture layer is penetrated. The formed sheet has a decreased clarity.

[0096] Example 3 It is basically the same as the steps of Example 2, except for steps (S.6) to (S.8). Steps (S.6) to (S.8) of this example are combined into one step (S.6) as follows: (S.6) Convey the SPC sheet obtained in the previous step to the fourth roll coater, and make the coating roll of the fourth roll coater roll 155 g / m 2 of the resin liquid (the resin liquid contains: 90% DowCorning 65 Additive, 5% photoinitiator 184, 0.5% photoinitiator TPO, 4.5% diluent hydroxyethyl acrylate) on the surface of the thickness adjustment layer to form a texture layer.

[0097] Example 4 It is basically the same as the steps of Example 2, except for (S.8). The rolling directions of the two coatings are the same. Steps (S.6) to (S.8) of this example are as follows: (S.6) Convey the SPC sheet obtained in the previous step to the fourth roll coater, and make the coating roll of the fourth roll coater roll 80 g / m 2 of the resin liquid (the resin liquid contains: 90% Dow Corning 65 Additive, 5% photoinitiator 184, 0.5% photoinitiator TPO, 4.5% diluent hydroxyethyl acrylate) on the surface of the thickness adjustment layer along the conveying direction of the SPC sheet (the rotation direction of the roll itself is clockwise) to form the base part of the texture layer; (S.7) After coating the first layer of resin liquid, make the SPC sheet convey forward along the surface of the conveying equipment, and ensure that before conveying to the next roll coater, the fourth roll coater does not apply any force to the resin liquid; (S.8) Convey the SPC sheet obtained in the previous step to the fifth roll coater, and make the coating roll of the fifth roll coater continue to roll 75 g / m 2 of the resin liquid (the resin liquid here is the same as the resin liquid in step (S.6)) along the conveying direction of the SPC sheet (the rotation direction of the roll itself is clockwise) to form the three-dimensional part of the texture layer.

[0098] Product testing: Surface abrasion resistance test: The test is carried out in accordance with the standard GT / T 18102-2020.

[0099] Surface scratch resistance index test: The test is carried out in accordance with the standard GT / T 18102-2020.

[0100] Clarity test: The test is carried out in accordance with the standard JIS K7374.

[0101] Touch depth level test.

[0102] Test for the proximity of touch feel to real wood grain.

[0103] Touch depth level test method and standard: Organize 15 evaluators to evaluate the touch depth of the board to be tested. Touch the surface of the board by hand, feel the unevenness of the board surface and the depth of the board groove, and record the evaluation results according to the level. The level with the largest number of people is the evaluation level of the final board.

[0104] The touch depth is divided into five levels. The five levels and the judgment criteria are shown in Table 1.

[0105] Note: From level 1 to level 5, the unevenness gradually decreases and the groove gradually becomes shallower.

[0106] Touch feel and real wood grain proximity test method and standard: Organize 15 evaluators to conduct a test on the proximity of touch feel to real wood grain. First, touch the wood grain of a real piece of wood, and then touch the surface of the board to be tested, evaluate its proximity, and record the evaluation results according to the level. The level with the largest number of people is the evaluation level of the final board.

[0107] The proximity of touch feel to real wood grain is divided into four levels. The five levels and the judgment criteria are shown in Table 2.

[0108] The test results of the surface wear resistance, scratch resistance and clarity performance of the boards in Examples 2-4 and Comparative Examples 1-4 are shown in Table 3 below: Result analysis: Compared with Example 2, Comparative Example 1 did not set a thickness adjustment layer, and the obtained board had a significant reduction in wear resistance, and the pattern layer was partially damaged, resulting in a significant decrease in clarity.

[0109] Compared with Example 2, in Comparative Example 2, the thickness adjustment layer was not cured and the texture layer was directly coated, and the clarity of the formed board structure was significantly decreased.

[0110] Comparative Example 3 Compared with Example 2, the texture layer was incompletely cured before applying the embossing liquid. In this case, it is not conducive to the immersion of the embossing liquid, resulting in a lower depth of the wood grain obtained finally, making the three-dimensional effect of the texture poor. Moreover, due to the poor immersion effect of the embossing liquid, the matching degree between the formed grooves and the wood grain pattern of the pattern layer decreases, resulting in a decrease in clarity.

[0111] Comparative Example 4 Compared with Example 2, the base part of the texture layer was not reserved. In this structure, the clarity of the board will be affected to a certain extent.

[0112] Example 3 Compared with Example 2, the texture layer was formed by a single coating method. During the coating process, the wear-resistant paint inside the texture layer was uneven, which had a certain impact on the clarity.

[0113] Example 4 Compared with Example 2, the texture layer was formed by coating twice in the same direction. Compared with the coating method in the opposite direction, the clarity was also affected.

[0114] For the touch depth level and the proximity of the touch feel to the real wood grain of the boards in Examples 2 - 4 and Comparative Examples 1 - 4, the test results are shown in Table 4 below: Example 5: Different from Example 2, in step (S.11), a steel brush with a thicker wire diameter (about 0.05 mm in diameter) was used to brush off the mixed part of the embossing liquid and the resin liquid, so as to form grooves with more protrusions on the surface of these parts; it was statistically found that the protrusions accounted for about 30% of the total inner surface area of the grooves.

[0115] Comparative Example 5: Different from Example 2, in step (S.11), a fine brush (the diameter of the hair is about 0.01 mm) was used to brush off the mixed part of the embossing liquid and the resin liquid, so as to form surface grooves at these parts. For the grooves formed in this way, there are basically no obvious protrusions on the surface. See the analysis by the laser profiler Figure 6 .

[0116] For the relevant performance tests of the boards in Example 5 and Comparative Example 5, the performance test results are shown in Table 5 below: As can be seen from Table 5, the clarity of the board in Comparative Example 5 is worse than that of the board in Example 5. Moreover, by further touching the surfaces of the boards in Example 5 and Comparative Example 5, the touch feel of Example 5 is closer to the real wood grain and is also closer to the real wood grain visually.

Claims

1. A board with a 3D texture structure, comprising at least a base material, a pattern layer, a wear-resistant layer and a topcoat layer from bottom to top; characterized in that, The wear-resistant layer includes a thickness adjustment layer and a texture layer located above the thickness adjustment layer. The texture layer includes a base part and a three-dimensional part. The pattern layer contains a number of connected or unconnected wood grain-shaped lines. The three-dimensional part includes a number of connected or unconnected wood grain-shaped grooves. At least part of the grooves correspond to the lines in one or more of the arrangement position, length, or width. The top of at least part of the topcoat layer is lower than the upper surface of the three-dimensional part. Among them, in the thickness adjustment layer, no groove structure is formed. On the texture layer, the grooves do not penetrate to ensure the integrity of the contact surface between the thickness adjustment layer and the texture layer. A base part is reserved below the three-dimensional part. Grooves are formed in the three-dimensional part, and no grooves are formed on the base part. There is a certain distance between the bottom of the groove and the thickness adjustment layer.

2. The sheet material with a 3D texture structure according to claim 1, characterized in that, The bottom and / or side walls of the groove have a number of protrusions.

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

4. The sheet having a 3D texture structure according to claim 2, wherein The side walls and the bottom of at least part of the grooves are connected at an obtuse angle.

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

6. A board having a 3D texture structure according to claim 1, characterized in that, At least part of the grooves include a hand-feeling deepening part in the middle, a visual simulation part at both ends, and a transition part located between the hand-feeling deepening part and the visual simulation part. The width of at least part of the visual simulation part is smaller than the width of the hand-feeling deepening part.

7. The sheet having a 3D texture structure according to claim 6, characterized in that, The depth of at least part of the visual simulation part of the grooves is smaller than the depth of the hand-feeling deepening part.

8. A board having a 3D texture structure according to claim 1 or 2, characterized in that The coating amount of the wear-resistant paint used for the thickness adjustment layer is 35 g / m 2 to 55 g / m 2 .

9. A sheet having a 3D texture structure according to claim 1, characterized in that, The coating amount of the wear-resistant paint used for the texture layer is greater than or equal to 150 g / m 2 .

10. Application of the board according to any one of claims 1 to 9 in a floor, a wall panel, or a ceiling panel.

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