Fiber-reinforced composite decorative plate, preparation method and preparation system

Abstract

The fiber-reinforced composite decorative plate comprises a decorative layer, a first adhesive film layer, a fiber-reinforced layer, a second adhesive film layer and an inorganic base plate which are sequentially arranged in a stacked mode, and the decorative layer, the fiber-reinforced layer and the inorganic base plate are compounded into a whole through the first adhesive film layer and the second adhesive film layer; the surface of the side, facing the second adhesive film layer, of the inorganic base plate is coated with a primer layer, the position between the primer layer and the second adhesive film layer is coated with a leveling layer, and the outer surface of the inorganic base plate is coated with a waterproof closed coating. When the composite decorative plate is subjected to external force such as impact, stretching and the like, the fiber reinforced layer in the composite decorative plate can dissipate energy, convert a damage form from brittle failure into ductile failure, disperse stress and avoid stress concentration, so that the composite decorative plate integrally has excellent toughness, impact resistance, energy absorption capacity and deformation resistance. In addition, the invention further provides a preparation method and a preparation system of the fiber-reinforced composite decorative plate.

Description

Technical Field

[0001] The present invention relates to the technical field of building materials, and particularly relates to a fiber-reinforced composite decorative board, a preparation method and a preparation system. Background Art

[0002] In the modern construction field, the selection of exterior wall materials is crucial, which not only concerns the aesthetic appearance of the building, but also plays roles such as protecting the main body of the building, heat insulation, waterproofing and fireproofing. At present, inorganic pre-coated boards and metal pre-coated exterior wall boards are relatively commonly used exterior wall materials.

[0003] An inorganic pre-coated board is a prefabricated board with a decorative coating made of an inorganic material board as the base material, through surface pretreatment and coating treatment on an automated production line. It has a high fire rating, strong weather resistance and is environmentally friendly and safe, but its appearance color and finish effect are relatively single, and its toughness is poor.

[0004] I. In terms of appearance: The current inorganic pre-coated boards have two finish effects, namely imitation stone and imitation metal. Among them, for the imitation stone finish effect, due to the use of a colorful or real stone paint coating system, it can only imitate the stone effect with dot-like patterns, and the accuracy of the imitation stone pattern is relatively low, and it is impossible to form a more three-dimensional finish effect (such as travertine) or a striped finish effect (such as black galaxy). The imitation metal finish effect is mainly formed by spraying or roll-coating fluorocarbon metal paint. Although the finished finish has a metallic luster, it lacks metallic texture.

[0005] II. In terms of toughness: Inorganic pre-coated boards use cement-based or calcium silicate boards as the base material. Although such inorganic boards have high strength, they lack toughness and are prone to cracking and breaking when impacted.

[0006] Metal pre-coated exterior wall boards usually use metal coils or sheets as the base material, and are prepared by surface pretreatment and then coating an organic coating on the surface or electroplating a layer of metal. They have strong decoration, realistic imitation of stone / wood grain, a wide range of color choices, and are lightweight and easy to dry-hang, but there are also many disadvantages. For example:

[0007] I. High thermal conductivity: Due to the good thermal conductivity of the metal material, in the high-temperature in summer and low-temperature in winter environments, it is more easily affected by the external temperature, and the heat transfer is faster, which is not conducive to the energy conservation and heat insulation of the wall.

[0008] II. Easy to deform: The linear expansion coefficient of the metal is high and is quite different from that of the wall. Under the influence of thermal expansion and contraction, it is extremely easy to deform. Especially for larger divided blocks, it is easier to have uneven decorative surfaces, which affects the exterior decoration effect of the building.

[0009] III. Insufficient rigidity: The thickness of metal pre-coated exterior wall boards is generally 1.2 - 3.5 mm, which has relatively high strength and toughness, good ductility but insufficient rigidity, is not impact-resistant, and is prone to concave and convex deformation when subjected to external forces.

[0010] IV. High cost: The metal plates used for the exterior wall need to be plates with special surface treatment, and the price is relatively high. Especially for the curtain wall system, in order to improve the overall strength and safety, plates with a thickness of not less than 3.0 mm are generally selected, and the cost performance is not high.

[0011] V. High production and construction difficulty: Metal pre-coated exterior wall panels generally require precise on-site surveying and mapping, reasonable design and drawing, and coded customized production and installation. Professional construction personnel and tools are required, and the production and construction are difficult and the flexibility is poor. Summary of the Invention

[0012] The purpose of the present invention is to provide a fiber-reinforced composite decorative board with stronger impact resistance and deformation resistance, and also to provide a preparation method and a preparation system for preparing the fiber-reinforced composite decorative board.

[0013] In order to achieve the above purpose, the technical solution adopted by the present invention is as follows:

[0014] A fiber-reinforced composite decorative board includes a decorative layer, a first adhesive film layer, a fiber-reinforced layer, a second adhesive film layer, and an inorganic substrate that are sequentially laminated. The first adhesive film layer and the second adhesive film layer composite the decorative layer, the fiber-reinforced layer, and the inorganic substrate into one body; a primer layer is coated on one side surface of the inorganic substrate facing the second adhesive film layer, a leveling layer is coated between the primer layer and the second adhesive film layer, and a waterproof sealing coating is coated on the outer surface of the inorganic substrate.

[0015] Further, the decorative layer is a soft porcelain layer or a thin metal layer.

[0016] Further, when the decorative layer is a soft porcelain layer, a polyurethane coating or a fluorocarbon varnish coating is coated on the surface of the decorative layer; when the decorative layer is a thin metal layer, a fluorocarbon coating or an anodic oxidation film layer is coated on the surface of the decorative layer.

[0017] Further, the thickness of the soft porcelain layer is 2-4 mm, the thickness of the thin metal layer is 0.15-0.4 mm, and the thickness of the coating or the anodic oxidation film layer on the surface of the decorative layer is 15-40 μm.

[0018] Further, the fiber reinforcement layer is composed of a surface mat with meshes, and the surface mat is selected from any one of polyester fiber mats, glass fiber mats, carbon fiber mats, and polyester composite mats; the first adhesive film layer and the second adhesive film layer are independently selected from any one of PES polyester-based hot melt adhesive films, PO polyolefin-based hot melt adhesive films, and TPU polyurethane-based hot melt adhesive films; the inorganic substrate is an asbestos-free fiber-reinforced calcium silicate board or an asbestos-free fiber cement flat plate, and the density of the inorganic substrate is 1.35 - 1.6 g / m3, the water absorption rate ≤ 28%, and the saturated water flexural strength ≥ 13 MPa; the primer layer is formed by coating any one of waterborne epoxy primers, waterborne polyurethane primers, and UV permeable primers; the leveling layer is formed by coating two-component solvent-free epoxy putty or UV putty; the waterproof sealing coating is a two-component waterborne epoxy coating or a two-component waterborne polyurethane coating.

[0019] The present invention also discloses a preparation method of a fiber-reinforced composite decorative board, comprising the following steps:

[0020] S1. Coating the waterproof sealing coating, the primer layer, and the leveling layer on the inorganic substrate to obtain a pre-coated substrate;

[0021] S2. Thermally pressing and bonding the fiber reinforcement layer on the decorative layer through the first adhesive film layer to obtain a semi-finished product A1 with initial adhesion, and thermally pressing and bonding the second adhesive film layer on the pre-coated substrate to obtain a semi-finished product B1 with initial adhesion;

[0022] Or, thermally pressing and bonding the first adhesive film layer on the decorative layer to obtain a semi-finished product A2 with initial adhesion, and thermally pressing and bonding the fiber reinforcement layer on the pre-coated substrate through the second adhesive film layer to obtain a semi-finished product B2 with initial adhesion;

[0023] S3. Stacking the semi-finished product A1 with initial adhesion and the semi-finished product B1 with initial adhesion together or stacking the semi-finished product A2 with initial adhesion and the semi-finished product B2 with initial adhesion together to obtain a semi-finished product with re-adhesion;

[0024] S4. Performing a thermocompression composite treatment on the semi-finished product with re-adhesion, and after thermocompression composite, performing cooling and shaping and trimming to obtain the fiber-reinforced composite decorative board.

[0025] Further, step S1 specifically includes:

[0026] S11. Roller coating the waterproof sealing coating on the outer surface of the inorganic substrate and curing the waterproof sealing coating to surface dryness;

[0027] S12. Performing a thickness-fixed sanding treatment on the inner surface of the inorganic substrate, and cleaning and removing dust after treatment;

[0028] S13. Roller coating the primer layer on the inner surface of the inorganic substrate and curing the primer layer to surface dryness;

[0029] S14. Roll coat the leveling layer on the primer layer and cure the leveling layer until it is thoroughly dry.

[0030] S15. Sand the leveling layer, clean and remove dust after the treatment to obtain the pre-coated substrate.

[0031] Further, step S2 specifically includes:

[0032] S21. Preheat the decorative layer, pre-coated substrate and fiber reinforcement layer to above 60°C, and preheat the first adhesive film layer and the second adhesive film layer to 70 - 130°C.

[0033] S22. Divide the decorative layer, pre-coated substrate, fiber reinforcement layer, first adhesive film layer and second adhesive film layer into two groups and stack them correspondingly, and then perform hot pressing and lamination on the two groups of materials respectively to form the initially sticky semi-finished product A1 and initially sticky semi-finished product B1 or form the initially sticky semi-finished product A2 and initially sticky semi-finished product B2. The hot pressing temperature is 120 - 200°C, the hot pressing pressure is 0.4 - 0.7 MPa, and the hot pressing duration is 10 - 30 s.

[0034] Further, in step S4:

[0035] The hot pressing and lamination treatment includes using a flat laminating hot press for pre-pressing treatment and using a flat plate type hot pressing and lamination machine for re-pressing treatment; during the pre-pressing treatment, the hot pressing temperature is 120 - 200°C, the hot pressing pressure is 0.6 - 1.2 MPa, and the hot pressing duration is 30 - 120 s; during the re-pressing treatment, the hot pressing temperature is 120 - 200°C, the hot pressing pressure is 10 - 30 tons, and the hot pressing duration is 20 - 60 s;

[0036] During the cooling and shaping treatment, first cool the plate surface temperature to 50°C by forced air cooling, and then cool the plate surface temperature to 30 - 35°C by natural cooling to complete the shaping.

[0037] The present invention also discloses a preparation system for a fiber-reinforced composite decorative board, including a substrate pretreatment device and a hot pressing and lamination device; the substrate pretreatment device includes an inorganic substrate loading machine, a first sander, a first dust collector, a first roll coater, a first infrared heater, a first turning machine, a second sander, a second dust collector, a second roll coater, a first UV curing machine, a third roll coater, a second UV curing machine, a third sander, a third dust collector and a pre-coated substrate unloading machine which are sequentially connected and arranged.

[0038] The hot pressing composite equipment includes a first initial adhesion module, a second initial adhesion module, a re-adhesion module, a fiber felt unwinder, and two groups of adhesive film unwinders; the first initial adhesion module includes a decorative layer loader, a fourth dust collector, a second infrared heater, a first flat laminating hot press, and a second turning plate machine arranged in butt joint in sequence; the second initial adhesion module includes a pre-coated substrate loader, a fifth dust collector, a third infrared heater, and a second flat laminating hot press arranged in butt joint in sequence; the two groups of adhesive film unwinders are respectively unwound to the first flat laminating hot press and the second flat laminating hot press, and the fiber felt unwinder is unwound to the first flat laminating hot press or the second flat laminating hot press;

[0039] The re-adhesion module includes a middle laminating machine, a third flat laminating hot press, a flat plate type hot pressing composite machine, a cooling conveyor, a trimming machine, and a finished product unloading machine arranged in butt joint in sequence, and the middle laminating machine is butted with the output sides of the first initial adhesion module and the second initial adhesion module.

[0040] The present invention has the following beneficial effects:

[0041] 1. The fiber reinforced layer is compounded in the decorative board. When the decorative board is subjected to external forces such as impact and tension, the fibers in the fiber reinforced layer can dissipate energy, change the failure form from brittle failure to ductile failure, thereby improving the energy absorption capacity of the decorative board and enhancing the overall toughness and impact resistance of the board; at the same time, the fiber reinforced layer has good connection and stress dispersion effects, can disperse stress when the decorative board is subjected to external force impact, avoid stress concentration, and effectively improve the strength and anti-deformation ability of the board.

[0042] 2. The decorative board uses a soft porcelain layer with a certain elasticity and toughness or a thin metal layer with good ductility and toughness as the decorative layer, and forms a "flexible surface and rigid bottom" sandwich composite structure in cooperation with structures such as the fiber reinforced layer and the inorganic substrate. Among them, the rigid inorganic substrate provides the main bearing capacity, and its high strength and high stiffness characteristics can enable the board to maintain a stable shape when subjected to external forces and bear most of the external loads, reducing the possibility of board deformation and damage. The fiber reinforced layer and the decorative layer are compounded on the inorganic substrate through the first and second adhesive film layers, which can improve the overall stiffness, reduce the strain of the board when subjected to external forces, and delay the deformation of the board.

[0043] 3. The decorative layer is a soft porcelain layer or a thin metal layer. When subjected to external force impact, it can undergo a certain amount of deformation, effectively absorb and dissipate energy. In addition, the decorative layer in cooperation with the fiber reinforced layer can also improve the integrity of the board. Even if the rigid inorganic substrate is damaged or fractured under external force, the overall board can still remain intact, broken but not scattered, and broken but not cracked, effectively improving the use safety of the board.

[0044] 4. When the decorative layer is a soft porcelain layer, the decorative panel can present various decorative effects such as natural stone, wood, ceramic tile, facing brick, metal, leather texture, etc. according to requirements; when the decorative layer is a thin metal layer, the decorative panel can retain the visual effect and texture of the pre-coated metal exterior wall panel, and overcome the problem of high cost of the pre-coated metal exterior wall panel, with relatively low overall production cost.

[0045] 5. The decorative panel can be cut, divided into blocks, and grooved on-site by woodworking machinery, and installed and connected by fasteners, with relatively convenient construction. It can also be compounded with thermal insulation materials to prepare a thermal insulation decorative integrated board, and constructed by the traditional "adhesive and anchor combination" method, with flexible installation. BRIEF DESCRIPTION OF THE DRAWINGS

[0046] Figure 1 It is a schematic structural diagram of the fiber-reinforced composite decorative panel of the present invention.

[0047] Figure 2 It is a schematic cross-sectional diagram of the fiber-reinforced composite decorative panel of the present invention.

[0048] Figure 3 It is a schematic structural diagram of the initially adhered semi-finished product A1 and initially adhered semi-finished product B1 of the present invention.

[0049] Figure 4 It is a schematic structural diagram of the initially adhered semi-finished product A2 and initially adhered semi-finished product B2 of the present invention.

[0050] Figure 5 It is a schematic structural diagram of the substrate pretreatment equipment of the present invention.

[0051] Figure 6 It is a schematic structural diagram of the hot pressing and compounding equipment of the present invention.

[0052] Description of main component symbols: 1. Decorative layer; 2. First adhesive film layer; 3. Fiber reinforcement layer; 4. Second adhesive film layer; 5. Inorganic substrate; 6. Primer layer; 7. Leveling layer; 8. Waterproof sealing coating; 9. Inorganic substrate loader; 10. First sander; 11. First dust collector; 12. First roll coater; 13. First infrared heater; 14. First turning machine; 15. Second sander; 16. Second dust collector; 17. Second roll coater; 18. First UV curing machine; 19. Third roll coater; 20. Second UV curing machine; 21. Third sander; 22. Third dust collector; 23. Pre-coated substrate unloader; 24. First initial adhesion module; 25. Second initial adhesion module; 26. Re-adhesion module; 27. Fiber felt unwinder; 28. Adhesive film unwinder; 29. Decorative layer loader; 30. Fourth dust collector; 31. Second infrared heater; 32. First flat laminating hot press; 33. Second turning machine; 34. Pre-coated substrate loader; 35. Fifth dust collector; 36. Third infrared heater; 37. Second flat laminating hot press; 38. Alignment laminator; 39. Third flat laminating hot press; 40. Flat panel hot press laminating machine; 41. Cooling conveyor; 42. Trimming machine; 43. Finished product unloader. Detailed implementation mode

[0053] The present invention will be further described below in conjunction with the accompanying drawings and the detailed implementation mode.

[0054] Embodiment 1

[0055] As Figure 1 , 2 shown, the present invention discloses a fiber-reinforced composite decorative board, which includes a decorative layer 1, a first adhesive film layer 2, a fiber reinforcement layer 3, a second adhesive film layer 4 and an inorganic substrate 5 that are sequentially laminated. The first adhesive film layer 2 and the second adhesive film layer 4 composite the decorative layer 1, the fiber reinforcement layer 3 and the inorganic substrate 5 into one body. A primer layer 6 is coated on the inner surface of the inorganic substrate 5, that is, the side surface facing the second adhesive film 4. A leveling layer 7 is coated between the primer layer 6 and the second adhesive film layer 4. A waterproof sealing coating 8 is coated on the outer surface of the inorganic substrate 5 including the side wall surface.

[0056] More specifically, the decorative layer 1 is a soft porcelain layer with a certain toughness and elasticity, that is, it is made of a modified inorganic powder composite building facing sheet. The modified inorganic powder composite building facing sheet is a flexible building decorative facing material made by using a polymer emulsion as an adhesive, adding inorganic powder, functional fillers and additives, and undergoing mixing and pulping, mold forming, baking cross-linking, and drying and demolding. Its fire protection grade can reach A2 level, non-combustible grade, and can present various natural stone facing effects including travertine effect and rock slab effect, as well as various apparent effects such as wood, ceramic tile, facing brick, metal, leather grain, etc. according to requirements. The thickness of the decorative layer 1 is set to 2-4 mm, and the surface of the decorative layer 1 is coated with a transparent polyurethane coating or a fluorocarbon varnish coating, and the thickness of the coating is set to 15-40 μm.

[0057] Both the first adhesive film layer 2 and the second adhesive film layer 4 are hot melt adhesive films, and each is independently selected from any one of PES polyester-based hot melt adhesive films, PO polyolefin-based hot melt adhesive films, and TPU polyurethane-based hot melt adhesive films. They both have excellent bonding properties and can firmly bond the decorative layer 1, the fiber reinforced layer 3, and the inorganic substrate 5 together.

[0058] The fiber reinforced layer 3 is composed of a surface mat with mesh holes. The surface mat is selected from any one of polyester fiber mats, glass fiber mats, carbon fiber mats, and polyester composite mats, and the gram weight is selected between 20 g / ㎡ - 100 g / ㎡, preferably 30 - 35 g / ㎡. It has characteristics such as porous, light weight, and flexible, and is easy to penetrate, has good film adhesion, and strong interlayer adhesion.

[0059] The inorganic substrate 5 is an asbestos-free fiber-reinforced calcium silicate board or an asbestos-free fiber cement flat plate. The density of the inorganic substrate 5 is 1.35 - 1.6 g / m 3 , the water absorption rate ≤ 28%, and the saturated water flexural strength ≥ 13 MPa. The primer layer 6 on the inner side of the inorganic substrate 5 is formed by coating any one of waterborne epoxy primer, waterborne polyurethane primer, and UV permeable primer to seal the pores of the inorganic substrate 5 and enhance the adhesion of the inorganic substrate 5. The leveling layer 7 is formed by coating a two-component solvent-free epoxy putty or a UV putty to level the surface and enhance the strength of the inorganic substrate 5. The waterproof sealing coating 8 is a two-component waterborne epoxy coating or a two-component waterborne polyurethane coating, which can prevent moisture from penetrating into the inorganic substrate 5 and causing conditions such as swelling and deformation.

[0060] Based on the decorative layer 1 with a certain elasticity or ductility and the rigid inorganic substrate 5, this composite decorative board has a "flexible surface and rigid bottom" sandwich composite structure, and has rich facing effects and stronger anti-deformation performance and anti-impact performance.

[0061] In terms of anti-deformation performance, among the various layer structures, the inorganic substrate 5 provides the main load-bearing capacity and can withstand most of the external loads. Its high strength and high stiffness characteristics enable the sheet to maintain a stable shape when subjected to external forces, and the possibility of sheet deformation and damage is relatively small. The fiber-reinforced layer 3, the first adhesive film layer 2, and the second adhesive film layer 4 play excellent connection and stress dispersion roles between the decorative layer 1 and the inorganic substrate 5. They can disperse stress when the decorative board is subjected to external force impact, avoid stress concentration, and effectively improve the strength and anti-deformation ability of the sheet. At the same time, the fiber-reinforced layer 3, the first adhesive film layer 2, and the second adhesive film layer 4 can also significantly improve the overall stiffness of the sheet, reduce the strain of the sheet when subjected to external forces, and delay the deformation of the sheet.

[0062] In terms of anti-impact performance, the elastic or ductile decorative layer 1 will undergo a certain amount of deformation when subjected to external forces, thereby absorbing and dissipating energy. The fibers in the fiber-reinforced layer 3 dissipate energy through sliding, stretching, etc., changing the failure mode from brittle failure to ductile failure. The cooperation of the two can effectively improve the energy absorption ability of the decorative board and enhance the overall toughness and anti-impact performance of the sheet.

[0063] In addition, the cooperation of the decorative layer 1 and the fiber-reinforced layer 3 can also improve the integrity of the sheet. Even if the rigid inorganic substrate 5 is damaged and fractured under external forces, the overall sheet can remain intact, broken but not scattered, and broken but not cracked, effectively improving the use safety of the sheet, making the application range of the sheet wider, such as being used as an explosion-proof board.

[0064] Preferably, in this embodiment, the decorative layer 1 is a soft porcelain layer with a thickness of 2 mm, and its surface finish effect is imitating natural stone. The surface of the decorative layer 1 is coated with a fluorocarbon varnish coating with a thickness of 25 - 30 μm. Both the first adhesive film layer 2 and the second adhesive film layer 4 are made of TPU polyurethane hot-melt adhesive film with a thickness of 0.2 mm and a melting temperature of 130 °C. The fiber-reinforced layer 3 is made of a polyester fiber felt with mesh holes, and its gram weight is 30 g / ㎡.

[0065] The inorganic substrate 5 preferably conforms to the high-density non-asbestos fiber cement slab in Class A, flexural strength grade R3 (saturated flexural strength ≥ 13 MPa), and impact strength grade C3 (impact strength P ≥ 1.8 KJ / m 2 ) in JC / T412.1 - 2018 "Fiber Cement Slabs - Part 1: Non-asbestos Fiber Cement Slabs", with a thickness of 8 mm and a density of 1.5 - 1.55 g / m 3 , and the water absorption rate ≤ 25%. The primer layer 6 is formed by coating with a UV-permeable primer, the leveling layer 7 is formed by coating with a UV putty, and the waterproof sealing coating 8 is a two-component waterborne epoxy coating, and the coating thickness > 35 μm.

[0066] Example Two

[0067] Different from the first embodiment, in this embodiment, the decorative layer 1 is a thin metal layer with a certain ductility, and the surface of the decorative layer 1 is coated with a fluorocarbon coating or an anodic oxidation film layer formed by an electrochemical oxidation process. That is, the decorative layer 1 is made of any one of pre-coated metal sheets including stainless steel plates, aluminum alloy plates, and galvanized steel plates, and can retain both the visual effect and texture of the pre-coated metal exterior wall panels.

[0068] The thickness of the decorative layer 1 is set to 0.15 - 0.4 mm, and the thickness of the coating or film layer on the surface of the decorative layer 1 is 20 - 40 μm. Among them, the thickness of the coating is preferably not less than 30 μm, and the thickness of the anodic oxidation film layer is preferably not less than 25 μm. Since the total thickness of the decorative layer 1 and its surface coating / film layer is much smaller than that of the existing pre-coated metal exterior wall panels, under the condition of having a similar appearance effect, it can overcome the problem of high cost of pre-coated metal exterior wall panels, reduce production costs, and the thermal conductivity is reduced, which is beneficial to the energy conservation and heat preservation of the wall.

[0069] Preferably, in this embodiment, the decorative layer 1 is a thin metal layer made of an aluminum alloy plate (material 1100H16), and the thickness is set to 0.3 mm. The outer surface of the decorative layer 1 is coated with a fluorocarbon coating with a thickness of 35 - 40 μm, and the inner surface of the decorative layer 1 is provided with an anodic oxidation film layer with a thickness not less than 25 μm. Both the first adhesive film layer 2 and the second adhesive film layer 4 are selected as TPU polyurethane hot melt adhesive films with a thickness of 0.3 mm and a melting temperature of 145 °C, and the fiber reinforced layer 3 is selected as a mesh polyester fiber felt with a gram weight of 35 g / ㎡.

[0070] Embodiment Three

[0071] The present invention also discloses a preparation method of a fiber-reinforced composite decorative board, including the following steps:

[0072] S1. Coating a waterproof sealing coating 8, a primer layer 6, and a leveling layer 7 on the inorganic substrate 5 to obtain a pre-coated substrate. Specifically, it includes:

[0073] S11. Roller-coating a two-component waterborne epoxy coating on the outer surface of the inorganic substrate 5 through a roller coater to form a waterproof sealing coating 8, with a roller-coating thickness not less than 35 μm and a coating consumption not less than 50 grams per square meter. Then, the waterproof sealing coating 8 is cured to surface dryness through an infrared heating machine.

[0074] S12. Conducting two passes of thickness-fixed sanding treatment on the inner surface of the inorganic substrate 5 through a sander, with 180-mesh sandpaper for one pass and 220-mesh sandpaper for one pass. After the treatment is completed, the inner surface of the inorganic substrate 5 is cleaned and dusted through a dust collector.

[0075] S13. Roller-coating a UV-permeable primer on the inner surface of the inorganic substrate 5 through a roller coater to form a primer layer 6, with a coating consumption of 0.05 - 0.06 kg / m 2Afterwards, the primer layer 6 is cured to surface dryness by a three-lamp UV curing machine, and the curing energy is not less than 220 mj / cm 2 .

[0076] S14. A leveling layer 7 is roll-coated on the primer layer 6 by a roll coater, and the coating consumption is 0.100 - 0.120 kg / ㎡. Afterwards, the leveling layer 7 is cured to through-dryness by a five-lamp UV curing machine, and the curing energy is not less than 220 mj / cm 2 .

[0077] S15. The leveling layer 7 is sanded by a sander, and the grit number of the sanding belt is 320 mesh. After the treatment is completed, it is cleaned and dust-removed by a dust collector to obtain a pre-coated substrate.

[0078] S2. As Figure 3 shown, the fiber reinforcement layer 3 is hot-pressed and bonded to the decorative layer 1 through the first adhesive film layer 2 to obtain a semi-finished product A1 with initial adhesion, and the second adhesive film layer 4 is hot-pressed and bonded to the pre-coated substrate to obtain a semi-finished product B1 with initial adhesion. Or as Figure 4 shown, the first adhesive film layer 2 is hot-pressed and bonded to the decorative layer 1 to obtain a semi-finished product A2 with initial adhesion, and the fiber reinforcement layer 3 is hot-pressed and bonded to the pre-coated substrate through the second adhesive film layer 4 to obtain a semi-finished product B2 with initial adhesion. However, regardless of Figure 3 , 4 which initial adhesion form is adopted, the following steps are required to be achieved:

[0079] S21. The decorative layer 1, the pre-coated substrate and the fiber reinforcement layer 3 are preheated to above 60°C, and the first adhesive film layer 2 and the second adhesive film layer 4 are preheated to 70 - 130°C, preferably 100 - 110°C. Among them, the first adhesive film layer 2 and the second adhesive film layer 4 are preferably TPU polyurethane-based hot melt adhesive films.

[0080] S22. According to the Figure 3 or Figure 4 grouping methods shown, the decorative layer 1, the pre-coated substrate, the fiber reinforcement layer 3, the first adhesive film layer 2 and the second adhesive film layer 4 are divided into two groups and stacked correspondingly, and then the two groups of materials are hot-pressed and compounded by a flat laminating press to form a semi-finished product A1 with initial adhesion and a semi-finished product B1 with initial adhesion or to form a semi-finished product A2 with initial adhesion and a semi-finished product B2 with initial adhesion. The hot-pressing temperature is 120 - 200°C, preferably 140 - 150°C, the hot-pressing pressure is 0.4 - 0.7 MPa, preferably 0.5 - 0.6 MPa, and the hot-pressing duration is 10 - 30 s, preferably 15 - 20 s.

[0081] S3. The semi-finished product A1 with initial adhesion and the semi-finished product B1 with initial adhesion are stacked together or the semi-finished product A2 with initial adhesion and the semi-finished product B2 with initial adhesion are stacked together to obtain a semi-finished product with re-adhesion.

[0082] S4. Perform hot pressing and lamination on the re-bonded semi-finished product. After hot pressing and lamination, carry out cooling and shaping, as well as cutting and trimming to obtain the fiber-reinforced composite decorative board.

[0083] Among them, the hot pressing and lamination process includes pre-pressing using a flat laminating hot press and re-pressing using a flat panel laminating hot press. During pre-pressing, the re-bonded semi-finished product can be tangentially contacted by the rollers of the flat laminating hot press to apply pressure and exhaust air, causing the structures of each layer to melt and bond, while extruding the bubbles during the interface fusion process to ensure the quality of the overall bonding.

[0084] During the pre-pressing process, the hot pressing temperature is 120 - 200 °C, preferably 160 - 180 °C, the hot pressing pressure is 0.6 - 1.2 MPa, preferably 0.6 - 0.8 MPa, and the hot pressing duration is 30 - 120 s, preferably 50 - 60 s. During the re-pressing process, the hot pressing temperature is 120 - 200 °C, preferably 150 - 160 °C, the hot pressing pressure is 10 - 30 tons, preferably 12 - 13 tons, and the hot pressing duration is 20 - 60 s, preferably 30 - 35 s.

[0085] During the cooling and shaping process, first use a cooling conveyor to force air-cool the board surface temperature to 50 °C, and then use natural cooling to reduce the board surface temperature to 30 - 35 °C to complete the shaping. On the one hand, it hardens and shapes the board and makes the board surface flat, and at the same time, it can also eliminate the internal stress generated between the materials of each layer during the hot pressing and lamination of the board.

[0086] Example 4

[0087] As Figure 5 、 6 shown, the present invention also discloses a preparation system for a fiber-reinforced composite decorative board, including a substrate pretreatment device and a hot pressing and lamination device.

[0088] The substrate pretreatment device is used for processing and manufacturing a pre-coated substrate. This device includes an inorganic substrate loader 9, a first sanding machine 10, a first dust collector 11, a first roller coater 12, a first infrared heater 13, a first turning machine 14, a second sanding machine 15, a second dust collector 16, a second roller coater 17, a first UV curing machine 18, a third roller coater 19, a second UV curing machine 20, a third sanding machine 21, a third dust collector 22, and a pre-coated substrate unloader 23, which correspondingly perform the processes of loading - sanding and dust removal - coating - drying and curing - turning - sanding and dust removal - coating - lamp curing - coating - lamp curing - sanding and dust removal - unloading.

[0089] Among them, several conveyors are centering conveyors, which can realize automatic centering while conveying materials, and facilitate the centering and overlapping of materials. The first UV curing machine 18 is a three-lamp curing machine, the second UV curing machine 20 is a five-lamp curing machine, the first sanding machine 10 and the second sanding machine 15 are both heavy-duty sanding machines, and the third sanding machine 21 is a floating sanding machine, so as to perform more detailed surface treatment.

[0090] The hot pressing composite equipment includes a first primary bonding module 24, a second primary bonding module 25, a re-bonding module 26, a fiber mat unwinder 26 and two sets of adhesive film unwinders 28. The first primary bonding module 24 and the second primary bonding module 25 are used to process and manufacture the primary bonding semi-finished product A1 and the primary bonding semi-finished product B1 or to process and manufacture the primary bonding semi-finished product A2 and the primary bonding semi-finished product B2. The first primary bonding module 24 includes a decorative layer feeder 29, a fourth dust removal machine 30, a second infrared heater 31, a first flat laminating hot press 32 and a second panel turning machine 33 which are sequentially connected by a conveyor. The second primary bonding module 25 includes a pre-coated substrate feeder 34, a fifth dust removal machine 35, a third infrared heater 36 and a second flat laminating hot press 37 which are sequentially connected by a conveyor. The two sets of adhesive film unwinding machines 28 unwind to the first flat laminating hot press 32 and the second flat laminating hot press 37 respectively to form the first adhesive film layer 2 and the second adhesive film layer 4 respectively, and the fiber felt unwinding machine 27 unwinds to the first flat laminating hot press 32 or the second flat laminating hot press 37 to form the fiber reinforced layer 3 respectively.

[0091] The re-bonding module 26 is used for processing re-bonding semi-finished products. The re-bonding module includes a centering laminating machine 38, a third flat laminating hot press machine 39, a flat layer hot pressing laminating machine 40, a cooling conveyor 41, a trimming machine 42 and a finished product unloading machine 43 which are connected in sequence through a conveyor. The centering laminating machine 38 is connected to the output side of the first primary bonding module 24 and the second primary bonding module 25.

[0092] Comparative Example

[0093] The comparative example is a conventional inorganic pre-coated plate with a fluorocarbon finish, and uses an inorganic substrate 5 of the same type and batch as that of Examples 1 and 2.

[0094] Related performance tests of Examples 1, 2 and Comparative Examples

[0095] The preferred fiber-reinforced composite decorative panels in Examples 1 and 2 were produced by the method provided in Example 3, and relevant performance tests were performed on the preferred fiber-reinforced composite decorative panels in Examples 1 and 2 and the comparative examples.

[0096] According to the relevant items of JG / T 396-2012 "Non-load-bearing fiber reinforced cement board for exterior wall", the relevant performances of the preferred solutions of Embodiments 1 and 2 and the comparative example were tested, and the test results are shown in Table 1:

[0097] Table 1

[0098]

[0099]

[0100] It can be seen from the basic test data that, compared with the comparative example, due to the rationality and particularity of the structure, the humidity deformation and water absorption performance of the systems of Example 1 and Example 2 are superior to those of the comparative example; while the durability has been significantly improved.

[0101] According to the test methods of flexural strength and impact strength in GB / T 7019-2014 "Test Methods for Fiber Cement Products", the substrates (asbestos-free fiber cement slabs), comparative examples, preferred solutions of Example 1 and Example 2 were tested respectively. The test results are shown in Table 2:

[0102] Table 2

[0103]

[0104] Note: When testing the flexural strength of the comparative example, Example 1 and Example 2, the decorative layer faces down; when testing the impact strength of the comparative example, Example 1 and Example 2, the decorative layer faces the pendulum.

[0105] It can be clearly seen from the test data that, compared with the substrate and the comparative example, the fiber-reinforced composite decorative boards provided in Example 1 and Example 2 have greatly improved in terms of impact strength and flexural strength; especially in Example 2, for the system using a thin metal layer as the decorative layer 1, the anti-deformation ability and toughness have been significantly increased.

[0106] Since the fiber-reinforced composite decorative board is formed by hot pressing and compounding, it is also necessary to evaluate the performance of its bonding structure. According to the technical requirements of 6.6 in JC / T 2561—2020 "Non-combustible Metal Composite Boards for Building Decoration", the 180° peel strength of the preferred solutions of Example 1 and Example 2 was tested. The test results are shown in Table 3:

[0107] Table 3

[0108]

[0109] Judging from the test data, the peel strength of the decorative layer 1 of this fiber-reinforced composite decorative board fully meets the performance requirements of exterior wall decorative plates.

[0110] Although the present invention has been specifically shown and described in combination with the preferred embodiments, those skilled in the art should understand that various changes can be made to the present invention in form and detail without departing from the spirit and scope of the present invention defined by the appended claims, and all of them fall within the protection scope of the present invention.

Claims

1. A fiber - reinforced composite decorative board, characterized in that: It includes a decorative layer, a first adhesive film layer, a fiber - reinforced layer, a second adhesive film layer and an inorganic substrate which are sequentially laminated. The first adhesive film layer and the second adhesive film layer composite the decorative layer, the fiber - reinforced layer and the inorganic substrate into one body; A primer layer is coated on one surface of the inorganic substrate facing the second adhesive film layer, a leveling layer is coated between the primer layer and the second adhesive film layer, and a waterproof sealing coating is coated on the outer surface of the inorganic substrate.

2. The fiber - reinforced composite decorative board according to claim 1, characterized in that: The decorative layer is a soft porcelain layer or a thin metal layer.

3. The fiber - reinforced composite decorative board according to claim 2, characterized in that: When the decorative layer is a soft porcelain layer, a polyurethane coating or a fluorocarbon varnish coating is coated on the surface of the decorative layer; when the decorative layer is a thin metal layer, a fluorocarbon coating or an anodic oxidation film layer is coated on the surface of the decorative layer.

4. The fiber - reinforced composite decorative board according to claim 2, characterized in that: The thickness of the soft porcelain layer is 2 - 4 mm, the thickness of the thin metal layer is 0.15 - 0.4 mm, and the thickness of the coating or the anodic oxidation film layer on the surface of the decorative layer is 15 - 40 μm.

5. The fiber - reinforced composite decorative board according to claim 1, characterized in that: The fiber - reinforced layer is composed of a surface mat with meshes, and the surface mat is selected from any one of polyester fiber mats, glass fiber mats, carbon fiber mats, and polyester composite mats; The first adhesive film layer and the second adhesive film layer are independently selected from any one of PES polyester - based hot - melt adhesive films, PO polyolefin - based hot - melt adhesive films, and TPU polyurethane - based hot - melt adhesive films; The inorganic substrate is an asbestos-free fiber-reinforced calcium silicate board or an asbestos-free fiber cement flat plate, and the density of the inorganic substrate is 1.35 - 1.6 g / m 3 , the water absorption rate ≤ 28%, and the saturated flexural strength ≥ 13 MPa; The primer layer is formed by coating any one of water - borne epoxy primer, water - borne polyurethane primer, and UV - permeable primer; The leveling layer is formed by coating two - component solvent - free epoxy putty or UV putty; The waterproof sealing coating is a two - component water - borne epoxy coating or a two - component water - borne polyurethane coating.

6. The preparation method of the fiber-reinforced composite decorative board according to any one of claims 1-5, characterized in that, It includes the following steps: S1. Coat the waterproof sealing coating, the primer layer and the leveling layer on the inorganic substrate to obtain a pre - coated substrate; S2. Thermally press and bond the fiber - reinforced layer to the decorative layer through the first adhesive film layer to obtain a semi - finished product A1 with initial adhesion, and thermally press and bond the second adhesive film layer to the pre - coated substrate to obtain a semi - finished product B1 with initial adhesion; Or, thermally press and bond the first adhesive film layer to the decorative layer to obtain a semi - finished product A2 with initial adhesion, and thermally press and bond the fiber - reinforced layer to the pre - coated substrate through the second adhesive film layer to obtain a semi - finished product B2 with initial adhesion; S3. Stack the semi - finished product A1 and the semi - finished product B1 together or stack the semi - finished product A2 and the semi - finished product B2 together to obtain a semi - finished product with re - adhesion; S4. Perform thermo - pressing and composite treatment on the semi - finished product with re - adhesion, and after thermo - pressing and composite, perform cooling and shaping and trimming to obtain the fiber - reinforced composite decorative board.

7. The preparation method of the fiber-reinforced composite decorative board according to claim 6, characterized in that, Step S1 specifically includes: S11. Roll - coat the waterproof sealing coating on the outer surface of the inorganic substrate and cure the waterproof sealing coating until it is surface - dry; S12. Perform thickness-fixed sanding treatment on the inner surface of the inorganic substrate, and clean and remove dust after the treatment; S13. Roll-coat the primer layer on the inner surface of the inorganic substrate, and cure the primer layer until it is surface-dry; S14. Roll-coat the leveling layer on the primer layer, and cure the leveling layer until it is fully dry; S15. Perform sanding treatment on the leveling layer, and clean and remove dust after the treatment to obtain the pre-coated substrate.

8. The preparation method of the fiber-reinforced composite decorative board according to claim 6, wherein Step S2 specifically includes: S21. Preheat the decorative layer, pre-coated substrate, and fiber reinforcement layer to above 60 °C, and preheat the first adhesive film layer and the second adhesive film layer to 70 - 130 °C; S22. Divide the decorative layer, pre-coated substrate, fiber reinforcement layer, first adhesive film layer, and second adhesive film layer into two groups and stack them correspondingly. Then, perform hot pressing and compounding on the two groups of materials respectively to form the initially sticky semi-finished product A1 and initially sticky semi-finished product B1, or form the initially sticky semi-finished product A2 and initially sticky semi-finished product B2. The hot pressing temperature is 120 - 200 °C, the hot pressing pressure is 0.4 - 0.7 MPa, and the hot pressing duration is 10 - 30 s.

9. The preparation method of the fiber-reinforced composite decorative board according to claim 6, wherein, In step S4: The hot pressing and compounding treatment includes pre-pressing treatment using a flat laminating hot press and re-pressing treatment using a flat plate type hot pressing and compounding machine; during the pre-pressing treatment, the hot pressing temperature is 120 - 200 °C, the hot pressing pressure is 0.6 - 1.2 MPa, and the hot pressing duration is 30 - 120 s; during the re-pressing treatment, the hot pressing temperature is 120 - 200 °C, the hot pressing pressure is 10 - 30 tons, and the hot pressing duration is 20 - 60 s; During the cooling and shaping treatment, first cool the plate surface temperature to 50 °C by forced air cooling, and then cool the plate surface temperature to 30 - 35 °C by natural cooling to complete the shaping.

10. The preparation system of the fiber-reinforced composite decorative board according to any one of claims 1-5, characterized in that, It includes: Substrate pre-treatment equipment, which includes an inorganic substrate loading machine, a first sanding machine, a first dust removal machine, a first roll coater, a first infrared heating machine, a first turning machine, a second sanding machine, a second dust removal machine, a second roll coater, a first UV curing machine, a third roll coater, a second UV curing machine, a third sanding machine, a third dust removal machine, and a pre-coated substrate unloading machine that are sequentially docked; Hot pressing and compounding equipment, which includes a first initial adhesion module, a second initial adhesion module, a re-adhesion module, a fiber felt unwinder, and two groups of adhesive film unwinders; the first initial adhesion module includes a decorative layer loading machine, a fourth dust removal machine, a second infrared heating machine, a first flat laminating hot press, and a second turning machine that are sequentially docked; the second initial adhesion module includes a pre-coated substrate loading machine, a fifth dust removal machine, a third infrared heating machine, and a second flat laminating hot press that are sequentially docked; the two groups of adhesive film unwinders are respectively unwound to the first flat laminating hot press and the second flat laminating hot press, and the fiber felt unwinder is unwound to the first flat laminating hot press or the second flat laminating hot press; The re-adhesion module includes a middle laminating machine, a third flat laminating hot press, a flat plate type hot pressing and compounding machine, a cooling conveyor, a trimming machine, and a finished product unloading machine that are sequentially docked, and the middle laminating machine is docked to the output sides of the first initial adhesion module and the second initial adhesion module.

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