Preparation method of highlight floor and highlight floor

Abstract

The invention discloses a preparation method of a highlight floor and the highlight floor. A high-hardness transparent wear-resistant layer (Shore Dgt; 78) is used as a basis and is combined with a high-hardness rubber roller (Shore Dgt; 45) high-gloss paint is accurately coated, then a baking and leveling process at the temperature of 80-120 DEG C is assisted, a paint film is fully leveled, an extremely smooth surface is formed, and finally after specific UV energy curing, the surface glossiness of the obtained floor can reach 70-80 GU, meanwhile, the floor has excellent wear resistance, a compact and completely-cured high-hardness paint film is formed on the surface of the floor, the surface energy is low, and the service life of the floor is prolonged. Pollutants are not easy to adhere and permeate, and the coating has good resistance to common household chemicals (such as cleaning agents, vinegar, alcohol and the like). In addition, by controlling the hardness of the rubber roller, the baking temperature, the coating amount, the UV energy and other key process parameters, the high consistency of the glossiness and the performance of the product during mass production can be guaranteed.

Description

Technical Field

[0001] This invention relates to the field of flooring manufacturing, and more particularly to a method for manufacturing a high-gloss flooring and the high-gloss flooring itself. Background Technology

[0002] PVC stone-crystal flooring is increasingly used in residential and commercial space decoration due to its environmental friendliness, wear resistance, water resistance, and rich decorative properties. Among them, high-gloss mirror-effect PVC flooring can further enhance the sense of luxury and visual expansion of a space, resulting in strong market demand.

[0003] Currently, the mainstream methods for producing high-gloss flooring mainly employ lamination or molding processes. Lamination involves attaching a pre-prepared high-gloss film layer to the substrate. While this method achieves good gloss, it suffers from problems such as insufficient adhesion between the film and substrate, easy peeling, and poor scratch resistance, and also has high production costs. Molding, on the other hand, uses a mold with a high-gloss texture to imprint the surface. However, this method requires extremely high mold precision, making product consistency control difficult, and the gloss is not durable, easily losing its shine due to wear during use.

[0004] Therefore, there is an urgent need to develop a production method for PVC flooring that is simple in process, cost-controllable, and capable of producing flooring with durable high gloss and excellent overall performance. Summary of the Invention

[0005] Purpose of the invention: In order to solve the problems existing in the prior art, the present invention provides a method for preparing high-gloss flooring and a high-gloss flooring that not only has excellent gloss, but also has the properties of stain resistance, chemical corrosion resistance and wear resistance.

[0006] Technical Solution: To achieve the above objectives, the present invention can adopt the following technical solution: a method for preparing a high-gloss floor, comprising the following steps: S1) A high-hardness wear-resistant layer is used to form a sheet substrate through an extruder; S2) Primer roller coating: High-gloss primer is roller coated on the surface of the substrate using a high-hardness rubber roller with a Shore D hardness greater than 45, and then the substrate enters the first heating oven for baking and leveling; the surface temperature of the substrate is controlled at 80℃ to 120℃; and then the substrate enters the first curing oven for curing.

[0007] S3) Topcoat roller coating: High-gloss topcoat is roller coated on the baked and leveled primer surface, and then the substrate enters the second heating oven for baking and leveling; the surface temperature of the substrate is controlled at 80℃ to 120℃; and then it enters the second curing oven for curing.

[0008] Furthermore, the high-hardness wear-resistant layer is a transparent sheet material with a Shore D hardness greater than 78. This high-hardness wear-resistant layer, as the outermost layer, is the basis for achieving high gloss and wear resistance.

[0009] The high-hardness wear-resistant layer is a high-hardness, high-gloss PVC wear-resistant layer. The PVC uses SG-5 grade resin produced by suspension polymerization. The wear-resistant layer has a light transmittance of 85-90%, a Shore hardness >75D, a tensile modulus of 3000-3400MPa, and a plasticizer content ≤3phr. It is bonded to the color film and substrate via online thermal bonding, and after UV treatment and grooving, the finished flooring is prepared.

[0010] Furthermore, the roller coating equipment used in steps S2 and S3 is equipped with a low surface tension coating roller. This roller helps the coating spread more evenly, reduces defects such as orange peel and pinholes, and improves the smoothness and gloss of the paint film.

[0011] Furthermore, in steps S2 and S3, a low-viscosity, high-gloss UV paint is used. The coating amount of the primer is 7-12 g / m², and the coating amount of the topcoat is 7-12 g / m². Precise control of the coating amount is key to ensuring uniform paint film thickness and consistent gloss.

[0012] Furthermore, the low-viscosity high-gloss UV paint has a UV viscosity of 400-800 mPa·s at 25°C; and its composition is an acrylate-based multifunctional resin.

[0013] Furthermore, the baking time in steps S2 and S3 is 10-20 seconds each.

[0014] Furthermore, the UV curing in step S4 includes: irradiating the primer layer with a UVA band light source at an energy of 200-400 mj / cm²; the primer is firmly cured and adheres tightly to the substrate, providing a smooth foundation for the topcoat. The primer is cured using LED lamps with a wavelength greater than 400nm, which generates little heat and prevents bubbling and deformation of the primer.

[0015] The topcoat layer is irradiated with a combination of UVA and UVV light sources, with UVA energy at 500-700 mJ / cm² and UVV energy at 700-1000 mJ / cm². UVA ensures complete curing of the topcoat, guaranteeing the strength and toughness of the film. UVV is specifically designed to rapidly cure the outermost layer of the topcoat, forming a high-hardness, high-density "protective shell." The topcoat is cured using a combination of gallium and mercury lamps, precisely delivering the required energy for high efficiency.

[0016] Furthermore, the board material is a PVC stone crystal flooring substrate.

[0017] The present invention also discloses a high-gloss floor made by the above preparation method.

[0018] Beneficial effects: The present invention has the following advantages: (1) By using a high-hardness transparent wear-resistant layer (Shore D>78) as a base, and combining it with a high-hardness rubber roller (Shore D>45) to precisely apply high-gloss paint, and then supplementing it with a baking and leveling process at 80-120℃, the paint film is fully leveled and forms an extremely smooth surface. Finally, after curing with specific UV energy, the resulting floor surface gloss can reach 70-80 GU, and it also has excellent wear resistance. (2) The floor surface forms a dense and fully cured high-hardness paint film with low surface energy, making it difficult for pollutants to adhere and penetrate. It has good resistance to common household chemicals (such as cleaning agents, vinegar, alcohol, etc.). (3) By controlling key process parameters such as rubber roller hardness, baking temperature, coating amount, and UV energy, this invention can ensure a high degree of consistency in product gloss and performance during mass production. Detailed Implementation

[0019] Example 1: A method for preparing high-gloss PVC flooring, the specific steps of which are as follows: S1) Substrate preparation: Select a high-hardness, high-gloss, wear-resistant PVC layer with a Shore hardness of 78D, a light transmittance of 88%, and a tensile modulus of 3200MPa. It is then laminated with decorative colored film and PVC substrate on an extrusion line through an online thermal bonding method to form a composite board. S2) Primer Roller Coating and Pre-curing: After cleaning the surface of the composite board, a low-viscosity, high-gloss UV primer is applied using a silicone roller with a Shore D hardness of 50 on a roller coater equipped with a Teflon low surface tension coating. The coating amount is controlled at 10 g / m². After roller coating, the board enters the first heating oven, where the surface temperature is controlled at 100℃ and the baking and leveling time is 15 seconds. Subsequently, it enters the first UV curing zone and is irradiated with an LED lamp with a wavelength of 405 nm and an irradiation energy of 300 mJ / cm². S3) Topcoat Roller Coating and Pre-curing: On the cured primer surface, a low-viscosity, high-gloss UV topcoat is applied using a roller coater with the same configuration. The coating amount is controlled at 10 g / m². The surface is then placed in the second heating oven, where the surface temperature is controlled at 105°C, and the baking and leveling time is 15 seconds. S4) Final Curing of Topcoat: The baked and leveled topcoat enters the second UV curing zone, where it is irradiated using a combination of a high-pressure mercury lamp and a gallium lamp. The high-pressure mercury lamp provides approximately 600 mJ / cm² of UVA band energy, and the gallium lamp provides approximately 850 mJ / cm² of UVV band energy. S5) Post-processing: After the fully cured board is cooled to room temperature, it is cut to a fixed length and grooved to obtain the finished high-gloss PVC flooring.

[0020] Example 2: The remaining steps are the same as in Example 1. The difference between this example and Example 1 is that key process parameters are adjusted to demonstrate its operability range: S1) A high-hardness, high-gloss, wear-resistant PVC layer with a Shore hardness of 76D and a light transmittance of 85% is selected. S2) The primer coating amount is controlled at 8 g / m²; the surface temperature of the board is controlled at 85℃ in the first heating oven, and the baking and leveling time is 20 seconds; the UV curing energy is 250 mJ / cm². S3) The topcoat application rate is controlled at 12 g / m²; the second heating tunnel controls the surface temperature of the board at 95℃, and the baking and leveling time is 10 seconds; S4) Final curing of topcoat: UVA band energy controlled at 550 mJ / cm², UVV band energy controlled at 750 mJ / cm².

[0021] Comparative Example 1: Commercially available ordinary high-gloss PVC film (Shore hardness approximately 65D) was used and bonded to the same PVC substrate as in Example 1 using a hot melt adhesive laminating machine at 150°C and 0.6MPa pressure. The film was then cut and grooved to obtain a high-gloss floor.

[0022] Comparative Example 2: Other process steps are the same as in Example 1, except that the coating process uses three layers of UV paint (low and medium coats) to coat the topcoat layer.

[0023] The following parameters were tested and compared between the high-gloss flooring prepared in Example 1 and Comparative Examples 1-2: Gloss: Surface gloss is measured at a 60° angle using a gloss meter; Chemical resistance: ASTM F925-13 (2020) Stain resistance: Red wine, coffee, soy sauce, and blue oil-based marker were selected as contaminants and exposed for 24 hours. Cleaning was performed using a damp cloth containing neutral detergent. After cleaning, the floors of the embodiments and comparative examples of this invention were observed and tested with a colorimeter. A rating of "extremely easy to clean" was given for total residual stains not exceeding 5%; a rating of "slight residue" was given for total residual stains between 5% and 20%; and a rating of "difficult to clean" was given for total residual stains exceeding 20%.

[0024] The test results are shown in Table 1: Table 1: Comparison of floor tests between Example 1 and Comparative Examples 1-2 Test Project 60° gloss Chemical resistance evaluation Stain resistance evaluation Example 1 80GU excellent Very easy to clean Comparative Example 1 65GU generally Slight residue Comparative Example 2 63GU generally Slight residue As can be seen from the data in Table 1: 1) The high-gloss floor prepared in Example 1 of this invention has a 60° gloss level (80 GU) that is significantly higher than that of Comparative Example 1 (65 GU) and Comparative Example 2 (63 GU). This indicates that the preparation method provided by this invention can effectively improve the optical smoothness and reflectivity of the floor surface, achieving a better high-gloss visual effect.

[0025] 2) In the chemical resistance evaluation, Example 3 was rated "Excellent," while Comparative Examples 1 and 2 were rated "Poor." This result demonstrates that the coating film formed through the specific processes of this invention (such as high-hardness roller coating, baking and leveling at 80-120℃, and multi-band UV curing) has a higher cross-linking density and a denser surface, which can more effectively resist the erosion of chemical reagents such as acids, alkalis, and solvents, thereby significantly improving the durability and applicability of the product.

[0026] 3) In the stain resistance evaluation, Example 3 reached the "extremely easy to clean" level, while Comparative Examples 1 and 2 were only at the "slight residue" level. This indicates that the low surface energy and high smoothness of the floor surface prepared by the present invention make it difficult for common stains to adhere and penetrate, making daily maintenance simpler and solving the practical application pain points of high-gloss floors being easy to get dirty and difficult to clean.

Claims

1. A method for preparing a high-gloss floor, characterized in that: Includes the following steps: S1) A high-hardness wear-resistant layer is used and the substrate is formed by extrusion; S2) Primer roller coating: High-gloss primer is roller coated onto the surface of the substrate using a high-hardness rubber roller with a Shore D hardness greater than 45, and then the substrate enters the first heating oven for baking and leveling; the surface temperature of the substrate is controlled at 80°C to 120°C; and then the substrate enters the first curing oven for curing. S3) Topcoat roller coating: High-gloss topcoat is roller coated on the baked and leveled primer surface, and then the substrate enters the second heating oven for baking and leveling; the surface temperature of the substrate is controlled at 80℃ to 120℃; and then it enters the second curing oven for curing.

2. The method for preparing high-gloss flooring according to claim 1, characterized in that: The high-hardness wear-resistant layer is a high-hardness transparent sheet with a Shore D hardness greater than 78.

3. The method for preparing high-gloss flooring according to claim 1 or 2, characterized in that: The high-hardness wear-resistant layer is a PVC high-hardness, high-gloss wear-resistant layer. The PVC uses SG-5 grade resin with suspension method. The wear-resistant layer has a light transmittance of 85-90, a Shore hardness >75D, a tensile modulus of 3000-3400MPa, and a plasticizer content ≤3phr. It is bonded to the color film and substrate through online heat bonding, and after grooving by UV treatment, the finished flooring is prepared.

4. The method for preparing high-gloss flooring according to claim 1, characterized in that: The roller coating equipment used in steps S2 and S3 is equipped with a low surface tension coating roller with a surface tension value of 36-38 dyn / cm.

5. The method for preparing high-gloss flooring according to claim 1, characterized in that: In steps S2 and S3, a low-viscosity, high-gloss UV paint is used. The coating amount of the primer is 7-12 g / m², and the coating amount of the topcoat is 7-12 g / m².

6. The method for preparing high-gloss flooring according to claim 5, characterized in that: The low-viscosity high-gloss UV paint has a UV viscosity of 400-800 mPa·s at 25°C; its composition is an acrylate multifunctional resin.

7. The method for preparing high-gloss flooring according to claim 1, characterized in that: The baking time in steps S2 and S3 is 10-20 seconds.

8. The method for preparing high-gloss flooring according to claim 1, characterized in that: The UV curing in step S4 includes: irradiating the primer layer with a UVA band light source with an energy of 200-400 mj / cm²; and irradiating the topcoat layer with a combination of UVA and UVV band light sources, wherein the UVA band energy is 500-700 mj / cm² and the UVV band energy is 700-1000 mj / cm².

9. The method for preparing high-gloss flooring according to any one of claims 1-8, characterized in that: The board material is a PVC stone crystal flooring substrate.

10. A high-gloss floor made by the preparation method according to any one of claims 1-9.