Moisture-proof anti-deformation melamine decorative plate and production process

Abstract

The invention belongs to the technical field of building decoration materials, and particularly relates to a damp-proof anti-deformation melamine decoration plate and a production process. The invention relates to a moisture-proof and deformation-resistant melamine decorative plate which comprises a wood base material layer, a nano silicon resin coating, a melamine impregnated paper layer, a glass fiber gridding cloth layer and a polyurethane resin layer which are sequentially compounded from bottom to top. The production process of the melamine decorative plate comprises the following steps: (1) sequentially carrying out microwave drying, vacuum drying and hot air circulation treatment on a wood base material; (2) performing electrostatic spraying on nano silicon resin and performing segmented curing; (3) carrying out gradient hot pressing on the melamine impregnated paper; (4) carrying out plasma treatment on the glass fiber gridding cloth and coating a silane coupling agent; and (5) gradient ultraviolet curing of polyurethane resin. According to the invention, the moisture resistance is obviously improved, the deformation resistance is greatly enhanced, the interlayer bonding strength is effectively improved, the coating and treatment process effects are comprehensively optimized, and the overall wear resistance, hardness and appearance quality of the decorative plate are improved.

Description

Technical Field

[0001] The invention belongs to the technical field of building decoration materials, and particularly relates to a moisture-proof and deformation-resistant melamine decorative board and a production process. Background Art

[0002] In the field of decorative materials, melamine decorative panels are widely used in furniture manufacturing, interior decoration, and other applications due to their aesthetics and durability. However, existing melamine decorative panels often face some technical problems that need to be solved in actual use.

[0003] 1. Inadequate moisture resistance: Traditional melamine decorative panels lack precise control over the moisture content and density of the wood substrate, making them susceptible to moisture. High humidity allows moisture to penetrate the panels, causing them to swell and deform, impacting their appearance and performance. For example, in the humid southern regions, conventional melamine decorative panels can warp at the edges after a period of use, severely impacting the decorative effect.

[0004] 2. Limited deformation resistance: Existing decorative panels have flaws in the material composition and structural design of the functional layers, making them ineffective in resisting deformation caused by external factors. For example, in environments with large temperature fluctuations, the panels can generate significant internal stress due to thermal expansion and contraction, leading to deformation and reducing their dimensional stability. This not only affects the panel's installation accuracy but can also cause gaps between adjacent panels, affecting the overall aesthetics.

[0005] 3. Poor bonding strength between layers: Incomplete lamination processes between layers result in insufficient bonding strength. During daily use, when subjected to external forces, the layers are prone to delamination, shortening the lifespan of the decorative panels. For example, during transportation or installation, even a slight collision can cause the melamine-impregnated paper layer to separate from the other layers.

[0006] 4. Imperfect coating and treatment processes: The coating materials and treatment processes used in some decorative panels fail to fully deliver their protective and decorative functions. For example, traditional resin coatings may not effectively block moisture penetration and have poor wear resistance. Over time, these coatings are prone to wear and tear, affecting the aesthetics and protective properties of the decorative panels. Furthermore, the process parameters used in the treatment of each layer are not optimized, failing to fully enhance material performance.

[0007] In summary, the existing melamine decorative panels have deficiencies in terms of moisture resistance, deformation resistance and layer bonding, and are difficult to meet the increasing market demand. Therefore, the development of a melamine decorative panel with excellent moisture resistance and deformation resistance is of great practical significance. Summary of the Invention

[0008] The purpose of the present invention is to provide a moisture-proof and deformation-resistant melamine decorative board and a production process.

[0009] In order to achieve the above object, the present invention provides the following technical solutions:

[0010] A moisture-proof and deformation-resistant melamine decorative board comprises a wood base material layer, a nano-silicone resin coating, a melamine impregnated paper layer, a glass fiber mesh cloth layer and a polyurethane resin layer which are laminated in sequence from bottom to top;

[0011] Wooden substrate layer, moisture content ≤ 8%, density 800-850kg / m 3 ;

[0012] Nano-silicone resin coating, thickness 0.18-0.22mm, containing 15-17% phosphate-modified nano-alumina particles, particle size 65-75nm;

[0013] Glass fiber mesh cloth layer, fiber diameter 28-32μm, mesh number 38-42;

[0014] The polyurethane resin layer has a thickness of 0.09-0.11 mm and contains 39-41% of silane coupling agent KH-550 modified nano-silica with a particle size of 45-55 nm.

[0015] Furthermore, the wood substrate layer is:

[0016] (1) Microwave drying: power density 1.5-1.8W / cm 3 Process for 20-25 minutes;

[0017] (2) Vacuum drying: vacuum degree -0.07~-0.06MPa, 55-58℃ for 35-38min;

[0018] (3) Hot air circulation: 70-85℃, wind speed 3.2-3.8m / s.

[0019] Furthermore, the nano silicone resin coating is:

[0020] Electrostatic spraying: voltage 42-48kV, distance 270-280mm;

[0021] Staged curing: preheat at 50-55℃ for 12-14 minutes, and cure at 95-98℃ for 26-28 minutes.

[0022] Furthermore, the melamine impregnated paper layer is subjected to gradient hot pressing:

[0023] Stage 1: Maintain pressure at 125-128°C / 5.2-5.8 MPa for 9-11 minutes;

[0024] The second stage: maintain pressure at 155-158℃ / 8.2-8.8MPa for 12-14min.

[0025] Furthermore, the glass fiber mesh cloth layer is treated with argon plasma: power 1100-1150W, gas flow 22-24L / min, treatment 75-85s; coating 6-8g / m 2 Silane coupling agent KH-550.

[0026] Furthermore, the polyurethane resin layer is cured by gradient ultraviolet light, wherein:

[0027] 365nm wavelength 420-480mJ / cm 2 Irradiation 16-19s;

[0028] 254nm wavelength 720-780mJ / cm 2 Irradiation time: 9-11 seconds.

[0029] A production process for preparing moisture-proof and deformation-resistant melamine decorative panels comprises the following steps:

[0030] (1) The wooden substrate is subjected to microwave drying, vacuum drying and hot air circulation treatment in sequence;

[0031] (2) applying a nano-silicone resin coating by an electrostatic spraying process and curing;

[0032] (3) laminating the melamine impregnated paper layer to the substrate using a gradient hot pressing process;

[0033] (4) Plasma treatment of the glass fiber mesh cloth layer and coating with silane coupling agent KH-550;

[0034] (5) A polyurethane resin layer is formed by a gradient ultraviolet curing process.

[0035] Furthermore, the gradient hot pressing process in step (3) includes two stages, and vibration is applied during the hot pressing process, with a vibration frequency of 95-105 Hz and an amplitude of 0.34-0.36 mm.

[0036] Furthermore, the coating amount of the silane coupling agent in step (4) is 6-8 g / m 2 .

[0037] Furthermore, after the gradient ultraviolet curing in step (5) is completed, infrared assisted treatment is further performed, with an infrared wavelength of 3.5-4.5 μm and a power density of 0.9-1.1 W / cm 2 , the processing time is 6-7min.

[0038] The beneficial effects of the present invention are:

[0039] 1. Significantly improved moisture resistance. This decorative board effectively blocks moisture intrusion through precise control of the moisture content and density of the wood substrate layer and the judicious use of phosphate-modified nano-alumina particles in the nano-silicone resin coating. After 72 hours in an environment with a relative humidity of 90%, the water absorption rate is only 3-5%, far lower than the 10-15% water absorption rate of traditional melamine decorative boards. This greatly enhances moisture resistance, allowing it to maintain excellent performance in humid environments and reducing problems such as swelling and deformation caused by moisture.

[0040] 2. Significantly enhanced deformation resistance. The specific fiber diameter and mesh count of the glass fiber mesh layer, in conjunction with the nano-silica modified with the silane coupling agent KH-550 in the polyurethane resin layer, form a stable support structure within the board and enhance surface mechanical properties. Thermal cycling tests showed that after 50 cycles between -20°C and 60°C, the dimensional change rate was only 0.1-0.3%. Compared to the 0.5-1% change rate of traditional decorative panels, this demonstrates excellent deformation resistance, ensuring that the board maintains a stable shape and size despite temperature fluctuations.

[0041] 3. Effectively improve interlayer bonding strength. Targeted treatment processes are applied to each layer, such as argon plasma treatment of the fiberglass mesh layer and silane coupling agent coating, to promote interlayer chemical reactions and enhance chemical bonding. Interlayer peel strength tests show that this decorative panel achieves a peel strength of 5-7 N / mm, exceeding the 3-5 N / mm of traditional decorative panels. This effectively prevents delamination between layers during use and significantly extends the service life of the decorative panel.

[0042] 4. Comprehensively optimize coating and treatment processes. From the electrostatic spraying and staged curing of the nano-silicone resin coating, to the gradient hot pressing of the melamine-impregnated paper layer, to the gradient UV curing and infrared-assisted treatment of the polyurethane resin layer, each layer's treatment process is precisely controlled to comprehensively enhance the performance of the board. The nano-silicone resin coating has a wear resistance of 5,000-6,000 times, compared to the 3,000-4,000 times of traditional coatings. The polyurethane resin layer is 10-20% harder than traditional processes, while the melamine-impregnated paper layer has a stronger bond, improving the overall wear resistance, hardness, and appearance of the decorative board. BRIEF DESCRIPTION OF THE DRAWINGS

[0043] Figure 1 Schematic diagram of the structure of moisture-proof and deformation-resistant melamine decorative board.

[0044] Figure 2 For the performance of the examples and comparative examples (peel strength (N / mm 2 ), wear resistance (number of revolutions), moisture resistance deformation rate (%)) comparison line chart. DETAILED DESCRIPTION

[0045] The technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention; it is obvious that the described embodiments are only part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.

[0046] Example 1

[0047] 1. Wood substrate treatment

[0048] Microwave drying: Select a wooden substrate and place it in a microwave drying device. Set the power density to 1.65W / cm 3 At this power density, the water molecules inside the wood can be effectively vibrated, accelerating water evaporation while avoiding excessive damage to the wood structure. The treatment lasted for 23 minutes, initially reducing the moisture content of the wood.

[0049] Vacuum Drying: After microwave drying, the wood is transferred to a vacuum drying device. The vacuum level is set to -0.063 MPa and the temperature is 57°C for 36 minutes. Under these vacuum and temperature conditions, the boiling point of water is lowered, removing any residual moisture from the wood and precisely controlling the moisture content to ensure that the wood substrate meets the required moisture content.

[0050] Hot air circulation: Place the vacuum-dried wood into a hot air circulation oven, set the temperature to 75°C, and the wind speed to 3.6m / s. Through hot air circulation, the moisture inside and on the surface of the wood is evenly distributed. Continue processing until the moisture content reaches 7.2%. At this point, the moisture content of the wood substrate is ≤8%, and the density is between 800-850kg / m 3 , providing a basis for the subsequent composite layers.

[0051] 2. Nano silicone coating

[0052] Electrostatic spraying: Prepare the nano-silicone resin coating and apply it using an electrostatic spray process. Set the spray gun voltage to 45kV and maintain a distance of 275mm from the wood substrate. Under these parameters, the coating particles are evenly adsorbed to the wood substrate by electrostatic action, forming a coating with a thickness of 0.20mm, which is within the range of 0.18-0.22mm and effectively utilizes the protective properties of the nano-silicone resin coating.

[0053] Staged curing: After spraying, the panels enter the curing stage, initially preheating at 53°C for 13 minutes. This low-temperature preheating helps the solvent in the coating evaporate slowly, allowing the coating to initially form a stable structure. The temperature is then raised to 97°C and cured for 27 minutes. This high-temperature stage promotes full cross-linking of the resin in the coating, forming a nano-silicone resin coating. This coating contains 15-17% phosphate-modified nano-alumina particles with a particle size of 65-75nm. These particles are evenly dispersed throughout the coating, enhancing its waterproof and wear-resistant properties.

[0054] 3. Melamine impregnated paper hot pressing

[0055] Stage 1: Melamine-impregnated paper and nano-silicone-coated sheets are placed in a hot press. The temperature is set at 126°C and the pressure is 5.5 MPa. The pressure is maintained for 10 minutes, while vibration is applied at a frequency of 100 Hz and an amplitude of 0.35 mm. During this stage, the relatively low temperature and pressure allow the impregnated paper to initially bond to the coating. Vibration effectively removes air and enhances adhesion.

[0056] Stage 2: After the first stage, the temperature is raised to 157°C and the pressure is increased to 8.5 MPa, and the pressure is maintained for 13 minutes. The higher temperature and pressure promote the full melting and penetration of the melamine-impregnated paper, firmly bonding with the coating to form a stable structure.

[0057] 4. Glass fiber mesh processing

[0058] Argon plasma treatment: Place the fiberglass mesh in an argon plasma treatment device, set the power to 1130W, the argon gas flow rate to 23L / min, and treat for 80 seconds. Under the action of the plasma, the molecular structure of the fiberglass mesh surface changes, generating a large number of active groups, creating conditions for subsequent silane coupling agent coating.

[0059] Coating of silane coupling agent KH-550: After plasma treatment, immediately apply 7g / m2 of silane coupling agent on the glass fiber mesh. 2 Silane coupling agent KH-550. Silane coupling agent can chemically react with the surface active groups of glass fiber mesh and subsequent polyurethane resin layer to enhance the bonding strength between layers.

[0060] 5. Polyurethane resin curing

[0061] Gradient UV curing: After the glass fiber mesh coated with silane coupling agent is laminated with the board, gradient UV curing is performed. First, use ultraviolet light with a wavelength of 365nm and an irradiation energy of 450mJ / cm 2The irradiation time is 17s. This wavelength of ultraviolet light triggers a partial photochemical reaction of the polyurethane resin, which initially solidifies the resin. Then, ultraviolet light with a wavelength of 254nm and an irradiation energy of 750mJ / cm 2 , irradiate for 10s. This wavelength of ultraviolet light further promotes the cross-linking reaction of the resin and fully cures the polyurethane resin.

[0062] Post-curing infrared assisted treatment: After UV curing, infrared assisted curing is used. The wavelength is set to 4.0μm and the power density is 1.0W / cm 2 The infrared radiation penetrates deep into the material, causing further reaction of the internal molecules of the polyurethane resin, eliminating stress and improving the uniformity and stability of the coating. The result is a polyurethane resin layer with a thickness of 0.09-0.11mm, containing 39-41% of nano-silica modified with silane coupling agent KH-550 and a particle size of 45-55nm.

[0063] Example 2

[0064] Wood substrate: The density of wood substrate is 800kg / m 3 After drying, the moisture content is 7.8%.

[0065] Microwave drying: power density was set at 1.6 W / cm 3 , process for 22 minutes.

[0066] Vacuum drying: the vacuum degree was set to -0.065 MPa, the temperature was 56°C, and the treatment time was 36 min.

[0067] Gradient hot pressing: the first stage temperature is 125℃, pressure is 5.4MPa, and pressure is maintained for 9min.

[0068] Argon plasma treatment: power 1100 W, gas flow rate 22 L / min, treatment time 75 s.

[0069] Gradient UV curing: 365nm wavelength UV radiation energy is 420mJ / cm 2 , irradiation time 16s.

[0070] The above is the adjustment of key parameters, and other parameters are the same as those in Example 1.

[0071] Example 3

[0072] Wood substrate: The density of wood substrate is increased to 850kg / m 3 , the moisture content dropped to 7.1%.

[0073] Microwave drying: power density increased to 1.7W / cm 3 , process for 24 minutes.

[0074] Vacuum drying: the vacuum degree was adjusted to -0.055 MPa, the temperature was 57°C, and the treatment was carried out for 37 min.

[0075] Gradient hot pressing: In the second stage, the temperature is increased to 158°C, the pressure is increased to 8.8 MPa, and the pressure is maintained for 14 minutes.

[0076] Argon plasma treatment: the power was increased to 1150 W, the gas flow rate was 24 L / min, and the treatment time was 85 s.

[0077] Gradient UV curing: 254nm wavelength UV radiation energy is 780mJ / cm 2 , irradiation time 11s.

[0078] The above is the adjustment of key parameters, and other parameters are the same as those in Example 1.

[0079] Comparative Example 1

[0080] This comparative example omitted the vacuum drying step and only carried out microwave drying (power density 1.65 W / cm 3 , treatment for 23 min) and hot air circulation (temperature 75° C., wind speed 3.6 m / s), and the other parameters are the same as in Example 1.

[0081] 2. Test results

[0082] Moisture content (%): 7.2 in Example 1 and 9.3 in Comparative Example 1. The higher moisture content indicates that the vacuum drying step is missing and the moisture in the wood is not fully removed, increasing the risk of the board being affected by moisture.

[0083] Thermal deformation rate (%): 0.08 for Example 1 and 0.42 for Comparative Example 1. The higher thermal deformation rate in Comparative Example 1 indicates that the high moisture content reduces the dimensional stability of the sheet material, making it more susceptible to deformation when the temperature changes.

[0084] Peel strength (N / mm 2 ): 12.5 for Example 1 and 7.9 for Comparative Example 1. The lower peel strength indicates that the change in moisture content affects the bonding between the layers, resulting in a decrease in overall performance.

[0085] Comparative Example 2

[0086] In this comparative example, the gradient hot pressing was omitted and replaced with a single-stage hot pressing process: 157° C. / 8.5 MPa holding pressure for 23 min. The remaining parameters were the same as those in Example 1.

[0087] 2. Test results

[0088] The color difference ΔE of the impregnated paper is 0.8 in Example 1 and as high as 3.6 in Comparative Example 2. The large color difference indicates that the single-stage hot pressing causes uneven heating of the impregnated paper, affecting color consistency.

[0089] Abrasion resistance (rotation number): Example 1 is 4200, while Comparative Example 2 is only 2650. The lower abrasion resistance rotation number indicates that the single-stage hot pressing cannot fully combine the melamine impregnated paper with the coating, reducing the abrasion resistance of the product.

[0090] Risk of hot pressing delamination: Example 1 showed no delamination, while comparative example 2 showed obvious delamination. This indicates that single-stage hot pressing is not conducive to forming a strong bond between the layers, increasing the risk of hot pressing delamination.

[0091] Comparative Example 3

[0092] This comparative example omitted the argon plasma treatment step and directly coated the silane coupling agent (7g / m 2 ). The remaining parameters are the same as those in Example 1.

[0093] 2. Test results

[0094] Silane coating uniformity (%): Example 1 is 98.5, while Comparative Example 3 is only 82.3. The lower uniformity indicates that the silane coupling agent is unevenly distributed on the surface of the glass fiber mesh due to the lack of argon plasma treatment, affecting the interlayer bonding stability.

[0095] Moisture and heat resistance test (48h): Example 1 showed no delamination, while comparative example 3 showed delamination, indicating that the uniformity of the silane coating was reduced and the interlayer bonding strength was insufficient, resulting in poor performance of comparative example 3 in the moisture and heat resistance test.

[0096] Adhesion after UV aging: Example 1 showed no decrease, while Comparative Example 3 decreased by 35%. This indicates that without argon plasma treatment, the adhesion between the glass fiber mesh and the polyurethane resin layer decreased significantly after UV aging, affecting the durability of the product.

[0097] The above examples and comparative examples demonstrate that the proper configuration of the various process steps and parameters in the present invention significantly impacts the performance of moisture-resistant and deformation-resistant melamine decorative panels. Strict adherence to the technical features outlined in the claims results in products with excellent performance in terms of moisture content control, peel strength, abrasion resistance, and resistance to moisture and deformation. However, omitting key steps or improperly adjusting parameters can lead to reduced product performance.

[0098] Table 1 Comparison of data between examples and comparative examples

[0099]

[0100] See the schematic diagram of the structure of moisture-proof and deformation-resistant melamine decorative board Figure 1 . Performance of Examples and Comparative Examples (Peel Strength (N / mm 2 ), wear resistance (number of revolutions), moisture resistance deformation rate (%)) comparison line chart see Figure 2 .

[0101] The above description is merely a preferred embodiment of the present invention; however, the scope of protection of the present invention is not limited thereto. Any person skilled in the art who, within the technical scope disclosed by the present invention, makes equivalent substitutions or modifications based on the technical solutions and improved concepts of the present invention shall be covered by the scope of protection of the present invention.

Claims

1. A moisture-proof and deformation-resistant melamine decorative board, characterized by: The invention comprises a wood base material layer, a nano silicone resin coating layer, a melamine impregnated paper layer, a glass fiber mesh cloth layer and a polyurethane resin layer which are laminated in sequence from bottom to top; Wooden substrate layer, moisture content ≤ 8%, density 800-850kg / m 3 ; Nano-silicone resin coating, thickness 0.18-0.22mm, containing 15-17% phosphate-modified nano-alumina particles, particle size 65-75nm; Glass fiber mesh cloth layer, fiber diameter 28-32μm, mesh number 38-42; The polyurethane resin layer has a thickness of 0.09-0.11 mm and contains 39-41% of silane coupling agent KH-550 modified nano-silica with a particle size of 45-55 nm.

2. The moisture-proof and deformation-resistant melamine decorative board according to claim 1, characterized in that: Wood substrate layer: (1) Microwave drying: power density 1.5-1.8W / cm 3 Process for 20-25 minutes; (2) Vacuum drying: vacuum degree -0.07~-0.06MPa, 55-58℃ for 35-38min; (3) Hot air circulation: 70-85℃, wind speed 3.2-3.8m / s.

3. The moisture-proof and deformation-resistant melamine decorative board according to claim 1, characterized in that: Nano silicone resin coating: Electrostatic spraying: voltage 42-48kV, distance 270-280mm; Staged curing: preheat at 50-55℃ for 12-14 minutes, and cure at 95-98℃ for 26-28 minutes.

4. The moisture-proof and deformation-resistant melamine decorative board according to claim 1, characterized in that: Melamine impregnated paper layer is hot pressed with gradient: Stage 1: Maintain pressure at 125-128°C / 5.2-5.8 MPa for 9-11 minutes; The second stage: maintain pressure at 155-158℃ / 8.2-8.8MPa for 12-14min.

5. The moisture-proof and deformation-resistant melamine decorative board according to claim 1, characterized in that: The glass fiber mesh cloth layer is treated with argon plasma: power 1100-1150W, gas flow 22-24L / min, treatment time 75-85s; Apply silane coupling agent KH-550.

6. The moisture-proof and deformation-resistant melamine decorative board according to claim 1, characterized in that: The polyurethane resin layer is cured by gradient UV light, wherein: 365nm wavelength 420-480mJ / cm 2 Irradiation 16-19s; 254nm wavelength 720-780mJ / cm 2 Irradiation time: 9-11 seconds.

7. A production process for preparing the moisture-proof and deformation-resistant melamine decorative board according to any one of claims 1 to 6, characterized in that: The following steps are involved: (1) The wooden substrate is subjected to microwave drying, vacuum drying and hot air circulation treatment in sequence; (2) applying a nano-silicone resin coating by an electrostatic spraying process and curing; (3) laminating the melamine impregnated paper layer to the substrate using a gradient hot pressing process; (4) Plasma treatment of the glass fiber mesh cloth layer and coating with silane coupling agent KH-550; (5) A polyurethane resin layer is formed by a gradient ultraviolet curing process.

8. The production process of moisture-proof and deformation-resistant melamine decorative panels according to claim 7, characterized in that: The gradient hot pressing process in step (3) includes two stages, and vibration is applied during the hot pressing process, with a vibration frequency of 95-105 Hz and an amplitude of 0.34-0.36 mm.

9. The production process of moisture-proof and deformation-resistant melamine decorative panels according to claim 7, characterized in that: The coating amount of the silane coupling agent in step (4) is 6-8 g / m 2 .

10. The production process of moisture-proof and deformation-resistant melamine decorative panels according to claim 7, characterized in that: After the gradient UV curing in step (5) is completed, infrared assisted treatment is further performed, with an infrared wavelength of 3.5-4.5 μm and a power density of 0.9-1.1 W / cm 2 , the processing time is 6-7min.

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