Wood-texture-imitating printed floor and preparation method thereof

Abstract

The invention relates to the technical field of building material manufacturing, in particular to a wood-texture-imitating printed floor and a preparation method thereof. A base material layer, a solid wood panel layer, a primer covering layer, a printing texture layer, a coloring protection layer and a three-dimensional wiredrawing texture layer are sequentially arranged on the wood-texture-imitating printing floor in a stacked mode. The solid wood panel layer is a solid wood veneer subjected to defect repair; the primer covering layer is a compact high-covering-power resin layer which completely covers the surface of the solid wood panel layer; the printed texture layer is a high-grade wood texture pattern layer; the coloring protection layer is a transparent imitation wood color resin layer; and the three-dimensional wiredrawing texture layer is a wiredrawing dent structure layer. The low-grade solid wood veneer subjected to defect repairing is adopted as the solid wood panel layer, and the compact primer covering layer with high covering power is matched, so that the raw material cost can be reduced, and repairing traces and potential flaws are completely covered; and through the synergistic effect of the printing texture layer, the coloring protection layer and the three-dimensional wiredrawing texture layer, the double wood-imitating simulation effect of vision and touch is achieved, and the requirement for high-quality indoor decoration is met.

Description

Technical Field

[0001] This invention relates to the field of building materials manufacturing technology, and in particular to a wood-grain patterned floor and its preparation method. Background Technology

[0002] Wood-look flooring, with its combination of natural decorative texture and excellent performance, has become an indispensable flooring material in modern interior decoration, and is widely used in residential, commercial spaces and other scenarios.

[0003] Existing surface decoration solutions for wood-look wood flooring mainly fall into two categories: one uses high-grade, defect-free solid wood veneer as the panel, which can present natural wood grain, but due to the increasing scarcity of high-grade solid wood resources, the raw material cost remains high, and a large number of low-grade solid wood veneers with defects such as dead knots and holes are discarded because they are difficult to use directly, resulting in a waste of wood resources; the other type directly prints decorations on the surface of the substrate, but due to the lack of targeted defect-covering structures and three-dimensional texture molding processes, it not only easily exposes the flaws of the substrate itself, but also the texture is only a two-dimensional visual effect without corresponding tactile feedback, resulting in poor three-dimensionality and simulation, making it difficult to meet the market's core demand for high-quality wood-look wood flooring.

[0004] Therefore, it is urgent for technical personnel to solve the above problems. Summary of the Invention

[0005] The purpose of this invention is to provide a wood grain patterned flooring that addresses the problems of scarcity and high cost of high-grade solid wood flooring raw materials, low utilization rate of low-grade solid wood veneers, incomplete coverage of defects, insufficient three-dimensional texture, and poor tactile simulation in existing designs.

[0006] This invention relates to a wood grain printed floor, characterized in that a substrate layer, a solid wood panel layer, a primer covering layer, a printed texture layer, a coloring protective layer, and a three-dimensional brushed texture layer are stacked sequentially from bottom to top; The solid wood veneer layer is a solid wood veneer that has been repaired for defects; The primer covering layer is a dense, high-coverage resin layer that completely covers the surface of the solid wood panel layer; The printed texture layer is a high-grade wood grain pattern layer; The coloring protective layer is a transparent or semi-transparent wood-colored resin layer; The three-dimensional brushed texture layer is a brushed indentation structure layer with the same texture direction as the printed texture layer.

[0007] As a further improvement to the technical solution disclosed in this invention, the raw material for the solid wood panel layer is a low-grade wood veneer, and the defect repair involves removing dead knots on the veneer and then filling them with wood blocks or wood chips of the same material, and scraping and filling holes with putty and smoothing the surface.

[0008] As a further improvement to the technical solution disclosed in this invention, the substrate layer is a multi-layer plywood with 3 to 11 layers, and the texture of each veneer is arranged in a cross pattern.

[0009] As a further improvement to the technical solution disclosed in this invention, the primer covering layer is a UV white resin layer; the coloring protective layer is a UV-cured wood-colored resin layer; and the sum of the thicknesses of the primer covering layer and the coloring protective layer is 0.1 to 0.5 mm.

[0010] As a further improvement to the technical solution disclosed in this invention, the wood grain printed floor also includes a wear-resistant topcoat layer; the wear-resistant topcoat layer is a high-transparency UV wear-resistant resin layer, which covers the surface of the three-dimensional brushed texture layer.

[0011] Furthermore, this invention also discloses a preparation method for preparing the above-mentioned wood grain printed flooring, comprising the following steps: S1. Panel treatment: Select solid wood veneer with dead knots and / or holes, remove the dead knots and fill them with glue of the same material, fill the holes with putty, and after smoothing, obtain the solid wood panel layer. S2, Lamination and bonding: The solid wood panel layer is bonded and fixed to the substrate layer to obtain the board blank; S3. Thickness sanding treatment: The slab is sanded to a fixed thickness to make its surface smooth and the total thickness meet the standard. S4. Coating and molding: A high-coverage resin is roller-coated onto the surface of the solid wood panel layer and UV-cured to form a primer covering layer. A high-grade wood grain pattern is then printed using a digital printing machine to form a printed texture layer. A UV-cured wood-colored resin is then roller-coated and partially cured to form a coloring protective layer. Finally, a three-dimensional brushed texture layer with the same direction as the printed texture layer is formed through an embossing process to obtain the finished product.

[0012] As a further improvement to the technical solution disclosed in this invention, in step S2, the solid wood panel layer and the substrate layer are bonded and fixed by a hot-pressing process with an adhesive coating. The hot-pressing temperature is 80-120°C, the pressure is 1-2 MPa, and the holding time is 2-6 hours.

[0013] Of course, as another modified design of the above technical solution, in step S2, the solid wood panel layer and the substrate layer are bonded and fixed by a cold pressing process with an adhesive coating, a cold pressing pressure of 1 to 1.5 MPa and a holding time of 4 to 8 hours.

[0014] As a further improvement to the technical solution disclosed in this invention, in step S4, the primer covering layer is formed by roller coating with a high-coverage resin and then cured; the printed texture layer is printed with a high-grade wood texture pattern by a digital printing machine.

[0015] As a further improvement to the technical solution disclosed in this invention, in step S4, the three-dimensional brushed texture layer is formed by pressing with a steel roller with fine grooves engraved on the surface, and the coloring protective layer is kept in an incompletely cured state or is softened during pressing.

[0016] Regarding the subject matter of the wood grain patterned flooring application, it can achieve at least the following beneficial technical effects in practical applications, specifically: 1) By using repaired solid wood veneer as the panel layer, low-grade solid wood veneer that would otherwise be discarded due to dead knots and holes can be fully utilized, thereby significantly reducing raw material costs and reducing waste of wood resources; and with a dense, high-coverage primer layer, repair marks and potential defects can be completely covered, preventing defects from being exposed, laying a smooth and clean foundation for subsequent printing and decoration, with a more thorough defect coverage and stronger product appearance consistency; 2) The printed texture layer accurately replicates the texture of high-grade wood, and with the transparent or semi-transparent coloring protective layer, it can restore the color and texture of natural wood; while the three-dimensional brushed texture layer gives the floor a realistic tactile feedback through the brushed groove structure, breaking the limitation of traditional flat printing that can only simulate visually, and achieving a dual simulation effect of visual and tactile, which meets the market demand for high-quality wood-look flooring.

[0017] Regarding the application for a method to prepare wood grain printed flooring, step S1, the panel treatment process, lays the foundation for subsequent defect concealment. Step S2, the lamination and bonding process, and step S3, the thickness sanding process, work together to ensure the overall flatness of the board and provide a base for the subsequent coating and molding process. Step S4, the coating and molding process, is precisely matched with the previous three processes. The primer covering layer can completely cover the repair marks on the solid wood panel layer. The printing of the printed texture, the application of the coloring protective layer, and the three-dimensional brushed texture embossing process are sequentially and orderly connected, ensuring accurate reproduction of the texture and color of high-grade wood. Through the synergistic matching of the three-dimensional brushed embossing process and the direction of the printed texture, the product's tactile and visual effects are consistent. The entire preparation process, from raw material pretreatment to finished product molding, is seamlessly connected, simultaneously achieving multiple goals: efficient utilization of low-grade wood resources, complete concealment of panel defects, excellent wood-like simulation effect, and stable product structure. Attached Figure Description

[0018] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0019] Figure 1This is an exploded view of the first embodiment of the wood grain printed flooring disclosed in this invention.

[0020] Figure 2 This is a schematic diagram of the structure of the first embodiment of the wood grain printed flooring disclosed in this invention.

[0021] Figure 3 This is an exploded view of the second embodiment of the wood grain printed flooring disclosed in this invention.

[0022] Figure 4 This is a schematic diagram of the structure of the second embodiment of the wood grain printed flooring disclosed in this invention.

[0023] 1-Substrate layer; 2-Solid wood panel layer; 3-Primer covering layer; 4-Printed texture layer; 5-Coloring protective layer; 6-Three-dimensional brushed texture layer; 7-Abrasion-resistant topcoat layer. Detailed Implementation

[0024] The technical solution of the present invention will be further described in detail below with reference to specific embodiments and accompanying drawings. Figure 1 , Figure 2 The exploded view and structural diagram of the first embodiment of the wood grain printed flooring disclosed in this invention are shown respectively. It can be seen that it is mainly composed of a substrate layer 1, a solid wood panel layer 2, a primer covering layer 3, a printed texture layer 4, a coloring protective layer 5, and a three-dimensional brushed texture layer 6, which are stacked sequentially from bottom to top.

[0025] The substrate layer 1 serves as the supporting base for the flooring and is preferably made of multi-layer plywood, with the number of layers strictly controlled between 3 and 11, and the grain of each veneer arranged in a cross pattern. Thanks to the cross pattern of the grain, the natural anisotropy of wood can be effectively offset, significantly reducing the shrinkage and expansion stress caused by changes in environmental temperature and humidity, and significantly improving the dimensional stability of the substrate layer 1, thus laying a good foundation for the overall structural stability of the flooring.

[0026] It is known that low-grade timber resources are abundant and inexpensive to acquire. However, a large number of low-grade veneers are discarded due to natural defects such as dead knots and holes, making them unsuitable for direct use in decorative panels under traditional processes. In this embodiment, a targeted defect repair process is used to precisely remove dead knot defects on low-grade veneers such as eucalyptus, poplar, fir, and birch. Wood blocks or sawdust of the same material are then used as fillers, bonded together with water-based polyurethane adhesive specifically for wood. Hole defects are filled using a wood putty made from a mixture of wood powder, adhesive, and hardener in specific proportions. After filling, the surface is sanded smooth to prepare the solid wood panel layer 2. The surface of the solid wood panel layer 2 has no obvious unevenness, and the roughness is controlled within a reasonable range. This allows for the full utilization of previously discarded low-grade solid wood veneers, significantly improving timber resource utilization. Furthermore, the use of the same material for filling ensures the consistency of the panel layer material, avoiding uneven coating adhesion due to differences in filler materials, thus laying a good foundation for subsequent decorative processes.

[0027] The primer covering layer 3 is a dense, high-coverage resin layer, preferably a UV white resin layer, with a thickness set at 0.05–0.2 mm. Its core function is to completely cover repair marks, color differences in the wood itself, and potential minor flaws on the surface of the solid wood panel layer 2. In addition, the UV white resin has the characteristics of fast curing speed, dense film formation, and strong hiding power. After being evenly coated by roller coating process, it is cured by UV curing machine to form a smooth and flat base, completely eliminating the exposure of defects and creating clean and uniform surface conditions for the clear presentation of the subsequent printed texture layer 4.

[0028] The coloring protective layer 5 is a transparent or semi-transparent UV-cured wood-colored resin layer with a thickness controlled between 0.05 and 0.3 mm. It works in conjunction with the primer covering layer 3, and the combined thickness of the two is strictly limited to 0.1 to 0.5 mm. Specific experimental verification shows that when the thickness is less than 0.1 mm, the primer's hiding power is insufficient, the coloring effect is uneven, and the wood color cannot be effectively reproduced; while when it is greater than 0.5 mm, the overall coating is easily too thick, which not only increases material costs but may also lead to cracking and peeling, while also affecting the forming accuracy of the subsequent three-dimensional brushed texture. By adding wood-colored pigments, the coloring protective layer 5 can realistically reproduce the color and texture of natural wood, and its transparent or semi-transparent properties will not obscure the details of the printed texture layer 4, achieving a natural fusion of color and texture.

[0029] The printed texture layer 4 is a high-grade wood grain pattern layer, only 1-5 μm thick, printed using a high-resolution digital printing machine. The application of digital printing technology can accurately replicate the natural textures of precious high-grade woods such as mahogany, oak, and walnut, including subtle features such as wood grain vessels, growth rings, and natural knots, resulting in clear and richly layered textures on the floor surface. Furthermore, because the printed texture layer 4 is directly printed onto a smooth substrate treated with the primer cover layer 3, there are no imperfections, resulting in a more coherent and natural pattern.

[0030] The three-dimensional brushed texture layer 6 is a brushed indentation structure layer with the same texture direction as the printed texture layer 4. It is the core element for achieving tactile simulation. The depth of its indentation is controlled between 20 and 50 μm, and the width is between 0.1 and 0.3 mm. The three-dimensional brushed texture layer 6 is formed by pressing with a steel roller with fine grooves engraved on its surface. The pressing time is precisely controlled when the coloring protective layer 5 is not fully cured or has undergone low-temperature softening treatment. At this time, the coloring protective layer 5 has a certain degree of flexibility and fluidity, and the grooves on the steel roller can be clearly pressed onto its surface, forming brushed indentations that perfectly match the direction of the printed texture.

[0031] It is particularly noteworthy that the concave structure of the three-dimensional brushed texture layer 6 precisely matches the duct and growth ring orientation of the printed texture layer 4. When users touch the floor surface, they can feel the same textured surface as natural wood, achieving a dual restoration of visual and tactile experience, thus significantly enhancing the wood-like simulation of the floor.

[0032] Figure 3 , Figure 4 The diagram shows an exploded view and a structural diagram of the second embodiment of the present invention. The core difference between this second embodiment and the first embodiment is the addition of a wear-resistant topcoat layer 7. The wear-resistant topcoat layer 7 covers the surface of the three-dimensional brushed texture layer 6, further enhancing the wear resistance of the floor and adapting to more usage scenarios.

[0033] The wear-resistant topcoat layer 7 is preferably a high-transparency UV wear-resistant resin layer, with a thickness set at 0.1–0.3 mm. The UV wear-resistant resin contains wear-resistant fillers such as nano-alumina, and after complete curing in a UV curing machine, it forms a transparent protective film with high hardness and strong wear resistance. In this way, while significantly improving the floor's wear resistance and extending its service life, it fully retains its wood-like texture, making the floor suitable for high-traffic areas such as shopping malls and offices.

[0034] The following is a detailed description of the method for preparing the wood grain printed flooring disclosed in this invention, which specifically includes the following steps: S1. Panel processing: First, select a single veneer of eucalyptus or poplar with a thickness of 1-3mm and dead knots and / or holes. Accurately locate the defect location using machine inspection. For dead knot defects, use a special tool to neatly remove them along the edge of the dead knot, creating a regular geometric shape for easy filling later. Select wood blocks or wood chips of the same material as the veneer, mix them with water-based polyurethane adhesive for wood to make a filler, fill it into the removed area and compact it, ensuring that the filler is flush with the veneer surface. For hole defects, use wood putty to fill them, and let it stand until fully cured. Finally, use a sander to smooth the entire panel, ensuring that the surface of the solid wood panel layer 2 is flat and smooth, providing a good base for subsequent lamination and coating.

[0035] Step S2, the lamination process, offers two options. The first option is a hot-pressing adhesive coating process: A water-based polyurethane adhesive is uniformly coated onto the surface of the substrate layer 1 (10-16mm thick), with the coating amount controlled at 150-200g / m². 2 The first method involves flattening the treated solid wood panel layer 2 onto the surface of the substrate layer 1 and then placing it in a hot press for hot pressing. The hot pressing temperature is set at 80–120℃, the pressure at 1–2 MPa, and the holding time at 2–6 hours. The second method is a cold pressing process with adhesive coating, suitable for temperature-sensitive panel materials. The cold pressing pressure is 1–1.5 MPa, and the holding time is 4–8 hours. The adhesive is slowly cured under pressure at room temperature. Although the production cycle is slightly longer, it can ensure the flatness of the panel to the greatest extent.

[0036] Step S3, thickness sanding: Due to the bonding between the layers, the laminated boards may have slight thickness deviations. A thickness sander is used to sand the upper surface of the boards (i.e., the surface of the solid wood panel layer 2). The sander preferably uses a double-sanding frame structure. The first sanding frame uses a 120-mesh sander for coarse sanding to remove surface impurities and protrusions; the second sanding frame uses a 240-mesh sander for fine sanding, ensuring a smooth and flat surface and that the total thickness meets design requirements (usually 12-18mm). This eliminates surface unevenness issues that may have arisen from previous processes, providing a flat and uniform base for subsequent coating and molding processes, ensuring uniform adhesion of subsequent coatings such as the primer cover layer 3 and the printed texture layer 4.

[0037] Step S4, Coating and Molding Process: First, UV white resin is roller-coated onto the sanded solid wood panel layer 2 using a roller coater. After curing in a UV curing machine, a primer covering layer 3 with a thickness of 0.05–0.2 mm is formed. Then, a high-grade wood grain pattern is printed using a high-resolution digital printing machine, forming a printed texture layer 4 with a thickness of 1–5 μm, ensuring clear reproduction of texture details. Next, UV-cured wood-colored resin is roller-coated to form a coloring protective layer 5 with a thickness of 0.05–0.3 mm. After curing in a UV curing machine, it, together with the primer covering layer 3, forms a uniform color. A smooth decorative base is prepared, and the total thickness of both is strictly controlled within 0.1 to 0.5 mm. Finally, a three-dimensional brushed texture is imprinted by attaching a steel roller with fine grooves on its surface to the slab surface. The imprinting pressure is controlled within 0.5 to 1 MPa. During imprinting, the coloring protective layer 5 remains in an incompletely cured state, or it is softened at a low temperature of 40 to 60°C, so that the grooves of the steel roller are clearly imprinted on the surface, forming a three-dimensional brushed texture layer 6 with a depth of 20 to 50 μm, a width of 0.1 to 0.3 mm, and consistent with the direction of the printed texture layer 4, thus obtaining the finished product of the first embodiment.

[0038] In the second implementation method, after the three-dimensional brushed texture layer 6 is formed, an additional layer of UV wear-resistant resin needs to be roller-coated and completely cured by a UV curing machine to form a wear-resistant topcoat layer 7 with a thickness of 0.1 to 0.3 mm, and finally the finished product is obtained.

[0039] The above description of the disclosed embodiments enables those skilled in the art to make or use the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A wood grain imitation printed floor, characterized in that, The base material layer, the solid wood panel layer, the primer covering layer, the printed texture layer, the colored protective layer and the three-dimensional wire drawing texture layer are sequentially stacked from bottom to top; The solid wood panel layer is a solid wood veneer with defects repaired; The primer covering layer is a dense high-hiding power resin layer, and completely covers the surface of the solid wood panel layer; The printed texture layer is a high-grade wood texture pattern layer; The colored protective layer is a transparent or semi-transparent wood-like color resin layer; The three-dimensional wire drawing texture layer is a wire drawing indentation structure layer consistent with the texture direction of the printed texture layer.

2. The parquet printed floor according to claim 1, characterized in that, The raw material of the solid wood panel layer is low-grade wood veneer, and the defect repair is to remove the knots on the veneer and then fill and glue with wood blocks or wood chips of the same material, or to scrape and fill the holes and then smooth.

3. The parquet print floor according to claim 1, wherein, The base material layer is a multi-layer plywood with 3-11 layers, and the veneer textures of each layer are cross arranged.

4. The parquet print floor according to claim 1, wherein, The primer covering layer is a UV white resin layer; the colored protective layer is a UV cured wood-like color resin layer; and the sum of the thicknesses of the primer covering layer and the colored protective layer is 0.1-0.5 mm.

5. The parquet print floor according to claim 1, wherein, It also includes a wear-resistant topcoat layer; the wear-resistant topcoat layer is a high-transparency UV wear-resistant resin layer covering the surface of the three-dimensional wire drawing texture layer.

6. A method of manufacturing a wood-like textured printed floor according to any one of claims 1-5, c h a r a c t e r i s e d in that, It comprises the following steps: S1, panel processing: selecting solid wood veneer with knots and / or holes, removing the knots and filling with the same material, scraping and filling the holes, and then smoothing to obtain the solid wood panel layer; S2, laminating: laminating and fixing the solid wood panel layer and the base material layer to obtain a board blank; S3, thickness setting and sanding: thickness setting and sanding the board blank to make the surface smooth and the total thickness meet the standard; S4, coating and forming: rolling high-hiding power resin on the surface of the solid wood panel layer, and forming the primer covering layer by UV curing, then printing high-grade wood texture pattern by digital printing machine to form the printed texture layer, then rolling UV cured wood-like color resin and partially curing to form the colored protective layer, and then forming the three-dimensional wire drawing texture layer consistent with the texture direction of the printed texture layer by embossing process to obtain the finished product.

7. The preparation method according to claim 6, characterized in that, In step S2, the laminating and fixing of the solid wood panel layer and the base material layer adopts a glue coating and hot pressing process, with a hot pressing temperature of 80-120°C, a pressure of 1-2 MPa, and a pressure maintaining time of 2-6 h.

8. The preparation method according to claim 6, characterized in that, In step S2, the laminating and fixing of the solid wood panel layer and the base material layer adopts a glue coating and cold pressing process, with a cold pressing pressure of 1-1.5 MPa and a pressure maintaining time of 4-8 h.

9. The preparation method according to claim 6, characterized in that, In step S4, the primer covering layer is formed by rolling high-hiding power resin and then curing; and the printed texture layer is printed by a digital printing machine.

10. The preparation method according to claim 6, characterized in that, In step S4, the three-dimensional wire drawing texture layer is formed by embossing with a steel roller having fine grooves on the surface, and the colored protective layer is kept in an uncured state or softened during embossing.

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