Preparation method of environment-friendly 3D printing three-dimensional surface floor

Abstract

The invention discloses a preparation method of an environment-friendly 3D printing three-dimensional surface floor, which comprises the following steps: S1, drawing a plane drawing of the floor, generating a 3D model of the floor by using a computer, and obtaining all layered structures and arrangement modes for forming the floor; and S2, raw materials for preparing the floor are prepared according to the 3D model of the floor in the S1, the raw materials are conveyed into a 3D printer for 3D printing, and all layered structures for the floor are printed. Through a sustainable raw material system, a formaldehyde-free laminating process, high-precision 3D printing texture forming, a three-layer environment-friendly protection layer, a bio-based edge sealing technology and an internet-of-things intelligent production system, production energy consumption is reduced by 40%, waste is reduced by 50%, closed-loop recovery is achieved, meanwhile, the international environment protection certification is met, the production efficiency is improved by 30%, and the production cost is reduced. And a full-chain green manufacturing scheme for synergistically improving the environmental protection performance, the production efficiency and the product quality is formed, and the double-carbon target requirement is met.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of 3D printing, in particular to a preparation method of an environmentally-friendly 3D-printed three-dimensional surface floor. BACKGROUND

[0002] Traditional floor preparation methods mostly use mold pressing or hot pressing forming process, which has problems such as low customization degree, long production cycle, and low raw material utilization rate. Although the prior art CN114329721A realizes the customized production of 3D-printed three-dimensional surface texture, there is still room for optimization in the raw material system, such as the traditional adhesive may contain harmful substances such as formaldehyde, and the energy consumption of the laminating process is high; the texture generation relies on a single scanning technology, and the precision and adaptability are limited; the edge sealing material lacks environmental protection performance; and the intelligent degree of the production process needs to be improved. In addition, the existing technology lacks systematic design for the whole life cycle environmental management of the floor, and the recycling rate is low after being discarded, which does not meet the development trend of green manufacturing. SUMMARY

[0003] The purpose of the present application is to provide a preparation method of an environmentally-friendly 3D-printed three-dimensional surface floor to solve the problems raised in the background art.

[0004] To achieve the above-mentioned purpose, the present application provides the following technical scheme: a preparation method of an environmentally-friendly 3D-printed three-dimensional surface floor, comprising the following steps:

[0005] S1, draw a plan drawing of the floor, generate a 3D model of the floor using a computer, and obtain all layered structures and arrangement modes for forming the floor;

[0006] S2, prepare raw materials for the floor according to the 3D model of the floor in S1, and convey them into a 3D printer for 3D printing to print all layered structures for the floor, then place all layered structures in order according to the arrangement mode generated by the 3D model in S1 and perform lamination to obtain a base material;

[0007] S3, 3D print a three-dimensional surface texture on the surface of the base material obtained in S2, and coat a protective paint layer on the texture surface to form a floor model;

[0008] S4, edge sealing and testing are performed on the floor model obtained in S3, and finally the floor model is delivered to obtain an environmentally-friendly 3D-printed three-dimensional surface floor.

[0009] Optionally, the raw materials in S2 include the following components by weight fraction:

[0010] 20-30 parts of bamboo fiber, 25-35 parts of bio-based polylactic acid (PLA), 8-12 parts of diatomite, 5-10 parts of nano-cellulose whiskers, 10-15 parts of water-based epoxy resin, and 60-90 parts of deionized water.

[0011] Optionally, the laminating process in S2 uses formaldehyde-free soy protein adhesive for interlayer bonding, the coating amount of the soy protein adhesive is 0.3-0.8 g / m², and after coating between adjacent layers, it is compacted by a hot press roller at 120-140°C and a pressure of 1.2-1.8 MPa, ensuring that the interlayer bonding strength is ≥2.0 MPa, and there is no glue opening after 168 hours of boiling test in boiling water.

[0012] Optionally, the three-dimensional surface texture in S3 is generated by the following steps:

[0013] P1 uses a three-dimensional scanner to scan the natural wood grain, stone grain or custom pattern provided by the customer, or creates a parameterized texture through an AI generation algorithm;

[0014] P2 uses texture optimization software for high-precision processing to form a vector texture file with a resolution of ≥600 dpi, supporting UV printing adaptation;

[0015] P3 uses a multi-nozzle 3D printing system to simultaneously print the texture and the gloss layer on the surface of the substrate, achieving a three-dimensional texture forming precision of 0.1 mm.

[0016] Optionally, the protective paint layer in S3 adopts a three-layer composite structure:

[0017] The inner layer is a water-based polyurethane wear-resistant layer (coating amount 15-25 g / m²), the middle layer is a self-cleaning layer containing nano titanium dioxide (coating amount 8-12 g / m²), and the outer layer is a fluorocarbon resin anti-staining layer (coating amount 5-8 g / m²), with a total VOC content of ≤30 g / L.

[0018] Optionally, the edge sealing in S4 uses a bio-based hot melt adhesive edge sealing technology:

[0019] The long edge uses a bamboo fiber reinforced thermoplastic starch (TPS) edge sealing strip, and the short edge uses a degradable polylactic acid (PLA) edge sealing strip, with an edge sealing temperature of 180-200°C, an edge sealing thickness of 1.2-1.8 mm, and an edge sealing strength of ≥1.5 MPa, ensuring that the edge sealing material has a degradation rate of ≥90% under industrial composting conditions for 6 months.

[0020] Optionally, the back of the substrate is provided with an intelligent humidity adjusting layer, which is composed of a breathable film containing diatomite / activated carbon composite particles, with a moisture absorption capacity of ≥150 g / m² per unit area, and can maintain the moisture content of the substrate stable at 8-12% in a humidity of 85%, meeting the JIS A1408 moisture-proof standard.

[0021] Optionally, the test steps in S4 include:

[0022] M1 Environmental performance test: the total volatile organic compounds (TVOC) is detected by gas chromatography-mass spectrometry ≤0.3mg / m³, and the content of heavy metals meets the CPSC children product safety standard;

[0023] M2 Durability test: the Taber abrasion tester is used to test the abrasion resistance rotation number ≥8000 rotations, and the drop ball impact test (1kg weight, 1m height) has no crack;

[0024] M3 Dimensional stability test: under the condition of-20℃ to 80℃ cyclic temperature difference, after 20 times of thermal cycle, the linear deformation rate is ≤0.2%.

[0025] Optionally, the production process of the 3D model of the computer-generated floor in S1 is realized through an Internet of Things intelligent system:

[0026] Q1 Customers upload texture design files through mobile APP, and the system automatically performs 3D modeling and printability analysis;

[0027] Q2 The 3D printer group receives instructions through a 5G network, automatically switches different material printing modules, and realizes the production of more than five textures in a day;

[0028] Q3 The inventory management system uses RFID to track the inventory of the base material, dynamically replenishes according to the order demand, and the inventory turnover rate is ≤25 days.

[0029] Optionally, the raw material in S2 is traced to a sustainable source, and after being discarded, it can be recycled through mechanical recycling or chemical degradation.

[0030] Compared with the prior art, the beneficial effects of the present application are as follows:

[0031] 1. The application provides a preparation method of an environmentally friendly 3D printed three-dimensional surface floor, which adopts a sustainable raw material system of bamboo fiber / biological PLA / diatomite, cooperates with a formaldehyde-free soy protein adhesive lamination process (bonding strength ≥ 2.0 MPa, no glue opening after boiling water test), combines AI generated parameterized texture and multi-nozzle 3D printing (precision 0.1 mm level, resolution ≥ 600 dpi), constructs a three-layer composite protection system (total VOC ≤ 30 g / L) and a biological edge sealing technology (degradation rate ≥ 90% in 6 months), assists with an intelligent humidity regulating layer (moisture absorption capacity ≥ 150 g / m², water content stability 8-12%) and an Internet of Things intelligent production system (single day switching ≥ 5 kinds of texture, inventory turnover rate ≤ 25 days), and finally forms a full life cycle environmental protection closed loop from 100% traceable / closed loop recycling of raw materials, 40% reduction of production energy consumption, and ≥ 70% utilization rate of waste conversion to biochar fuel, which reduces 50% waste compared with traditional processes, improves 30% production efficiency, meets international environmental protection certifications such as UL GREENGUARD Gold and ISO14064 carbon footprint, realizes the synergistic improvement of environmental protection performance, production efficiency and product quality, meets the green manufacturing demand under the 'double carbon' target, and has economic and social value.

[0032] 2. In the application, sustainable raw materials such as bamboo fiber, biological polylactic acid (PLA) and diatomite are used in combination with water-based epoxy resin to realize 100% traceability and closed loop recycling of raw materials, formaldehyde / benzene series release free in the production process, 40% reduction of carbon emissions compared with traditional processes, and ≥ 70% utilization rate of waste pyrolysis conversion to biochar fuel.

[0033] 3. In the application, the formaldehyde-free soy protein adhesive coating amount is only 0.3-0.8 g / m², combined with a hot pressing process of 120-140 ℃ / 1.2-1.8 MPa, the interlayer bonding strength is ≥ 2.0 MPa, and no glue opening is found after 168 hours of boiling water test, and the energy consumption is reduced by 25%.

[0034] 4. In the application, the AI algorithm is used to generate parameterized texture, and the multi-nozzle 3D printing system is used to realize 0.1 mm level precision three-dimensional texture forming, support UV printing adaptation, resolution ≥ 600 dpi, and meet the personalized customization demand.

[0035] 5. In the application, the inner layer water-based polyurethane wear-resistant layer (15-25 g / m²), the middle layer nano titanium dioxide self-cleaning layer (8-12 g / m²), and the outer layer fluorocarbon stain-resistant layer (5-8 g / m²) are combined, the total VOC is ≤ 30 g / L, and the UL GREENGUARD Gold certification is met.

[0036] 6. In the application, the bamboo fiber reinforced TPS long edge sealing strip and the PLA short edge sealing strip are combined, the sealing strength is ≥ 1.5 MPa, the industrial compost degradation rate is ≥ 90% in 6 months, and the environmental load is reduced by 70% compared with traditional PVC sealing.

[0037] 7. In this invention, the moisture absorption of the diatomaceous earth / activated carbon moisture-regulating layer on the back of the substrate is ≥150g / m², maintaining a moisture content of 8-12%, and the linear deformation rate is ≤0.2% when tested with a temperature difference cycle from -20℃ to 80℃, which meets the JISA1408 standard.

[0038] 8. In this invention, the rapid switching of 3D printer clusters is achieved through 5G network (≥5 textures per day), and the RFID inventory management system ensures a turnover rate of ≤25 days. Combined with the full automation of customer APP upload, AI modeling, and printability analysis, production efficiency is improved by 30%.

[0039] 9. In this invention, the raw materials are certified as sustainable sources, ISO14064 carbon footprint certification is obtained, and waste is mechanically / chemically degraded and recycled in a closed loop, forming a green closed loop from production to disposal, which reduces waste by 50% compared to traditional processes. Attached Figure Description

[0040] Figure 1 This is a flowchart illustrating the preparation method of the environmentally friendly 3D printed three-dimensional surface floor of the present invention. Detailed Implementation

[0041] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0042] Please see Figure 1 A method for preparing an environmentally friendly 3D printed stereoscopic surface floor includes the following steps:

[0043] S1. Draw a plan view of the floor, and use a computer to generate a 3D model of the floor to obtain all the layered structures and arrangements that form the floor;

[0044] S2. Prepare the raw materials for the floor according to the 3D model of the floor in S1, and send them into the 3D printer for 3D printing. Print all the layered structures of the floor. Then, arrange all the layered structures neatly according to the arrangement generated by the 3D model in S1 and laminate them to obtain the substrate.

[0045] S3. A three-dimensional surface texture is 3D printed on the substrate surface obtained in S2, and a protective paint layer is coated on the texture surface to form a floor model.

[0046] S4. The floor model obtained in S3 is edge-sealed and tested, and finally shipped out to obtain an environmentally friendly 3D printed three-dimensional surface floor.

[0047] To achieve personalized customization and environmentally friendly production, the method first performs step S1: draw floor plan paper through CAD software, and generate 3D model containing layered structure parameters using Brep algorithm, accurately obtain the three-dimensional arrangement coordinate system of all layered structures such as substrate layer, decorative layer, etc. This step realizes the accurate mapping of virtual modeling and physical production through digital twinning technology, ensuring that the model error is ≤0.05mm.

[0048] To optimize the environmental performance and processing adaptability of raw materials, in step S2, bamboo fiber 20-30 parts and bio-based PLA 25-35 parts are used as main materials, supplemented by diatomite 8-12 parts to enhance moisture absorption, nano-cellulose whiskers 5-10 parts to improve interlayer bonding strength, water-based epoxy resin 10-15 parts as adhesive medium, and deionized water 60-90 parts to form low-viscosity printing slurry. The formula is FSC certified, with VOC emission ≤50g / L during production process, reducing carbon footprint by 60% compared to traditional petroleum-based raw materials.

[0049] To improve interlayer adhesion strength and weather resistance, in the S2 lamination process, formaldehyde-free soy protein glue is used, with a precise coating amount of 0.3-0.8g / m². Through 120-140℃ hot press roller with a pressure of 1.2-1.8MPa, the interlayer bonding strength is ≥2.0MPa, and there is no delamination phenomenon after 168 hours of boiling water test, meeting the requirements of EN302 standard.

[0050] To achieve high-precision three-dimensional texture forming, in S3, a multi-nozzle 3D printing system is used to perform texture generation: P1 phase obtains customer's customized texture data through laser three-dimensional scanner, or generates parameterized wood grain / stone grain by AI algorithm; P2 phase uses NURBS surface reconstruction technology to generate ≥600dpi vector files; P3 phase realizes 0.1mm level precision texture and gloss oil co-extrusion printing through synchronous extrusion device, forming a three-dimensional surface with tactile texture.

[0051] To enhance surface protection performance, the protective paint layer adopts a three-layer composite structure: the inner layer of 15-25g / m² water-based polyurethane wear-resistant layer provides scratch resistance, the middle layer of 8-12g / m² nano-TiO2 self-cleaning layer realizes photocatalytic decomposition of pollutants, and the outer layer of 5-8g / m² fluorocarbon stain-resistant layer forms a low-surface-energy coating. The total VOC is ≤30g / L, and it passes the UL GREENGUARD Gold certification.

[0052] To achieve degradable edge sealing, in S4, bio-based hot melt adhesive technology is used: long edge uses bamboo fiber reinforced TPS edge sealing strip, short edge uses PLA edge sealing strip, forms 1.2-1.8mm thick edge sealing layer under 180-200℃ hot pressing, strength ≥1.5MPa. The edge sealing material has a degradation rate ≥90% under industrial composting conditions for 6 months, meeting the ASTM D6400 standard.

[0053] In order to regulate the humidity balance of the substrate, an intelligent humidity regulating layer is arranged on the back: the air permeable film composed of diatomite / activated carbon composite particles has a moisture absorption capacity of ≥150 g / m² per unit area, and can maintain the water content of the substrate at 8-12% in an environment with a humidity of 85%. The product has excellent moisture-proof performance according to the JIS A1408 standard test.

[0054] In order to ensure product reliability, the test steps include: M1 environmental performance test using GC-MS to detect TVOC ≤0.3 mg / m³; M2 durability test verified by Taber abrasion tester ≥8000 revolutions of wear resistance, no cracks in the falling ball impact test; M3 dimensional stability test after 20 thermal cycles under a temperature difference of-20°C to 80°C, linear deformation rate ≤0.2%.

[0055] In order to improve the intelligent level of production, the Internet of Things system is integrated in S1: Q1 stage customers upload texture design through APP, the system automatically performs 3D modeling and printability verification; Q2 stage 5G network controls 3D printer group to automatically switch material modules, realizing rapid switching of ≥5 kinds of textures per day; Q3 stage RFID inventory management system dynamically tracks substrate inventory, turnover rate ≤25 days.

[0056] In order to build a full life cycle environmental protection closed loop, all raw materials come from sustainable certified sources, after being discarded, they can be recycled as fillers after mechanical crushing, or converted into biofuels through chemical degradation, achieving a closed loop recycling rate of ≥85%.

[0057] In use:

[0058] Through the whole process cooperation of digital modeling-environmentally friendly raw material preparation-high precision 3D printing-intelligent lamination-stereoscopic texture forming-three layer protective coating-biological based edge sealing-intelligent humidity regulation-strict testing-Internet of Things production, the whole chain green manufacturing from design to production is realized. This scheme not only meets the needs of individual customization, but also realizes 40% reduction in production energy consumption and 50% reduction in waste through raw material innovation, process optimization and intelligent control, while the product meets multiple international environmental protection certifications, forming a synergistic improvement system of environmental performance, production efficiency and product quality, which meets the green manufacturing development trend under the "double carbon" target.

[0059] Although embodiments of the present application have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made therein without departing from the principles and spirit of the application, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A method for preparing an environmentally friendly 3D printed stereoscopic surface floor, characterized in that: Includes the following steps: S1. Draw a plan view of the floor, and use a computer to generate a 3D model of the floor to obtain all the layered structures and arrangements that form the floor; S2. Prepare the raw materials for the floor according to the 3D model of the floor in S1, and send them into the 3D printer for 3D printing. Print all the layered structures of the floor. Then, arrange all the layered structures neatly according to the arrangement generated by the 3D model in S1 and laminate them to obtain the substrate. S3. A three-dimensional surface texture is 3D printed on the substrate surface obtained in S2, and a protective paint layer is coated on the texture surface to form a floor model. S4. The floor model obtained in S3 is edge-sealed and tested, and finally shipped out to obtain an environmentally friendly 3D printed three-dimensional surface floor.

2. The method for preparing the environmentally friendly 3D printed stereoscopic surface floor according to claim 1, characterized in that: The raw materials in S2 include the following components in parts by weight: Bamboo fiber 20-30 parts, bio-based polylactic acid (PLA) 25-35 parts, diatomaceous earth 8-12 parts, nanocellulose whiskers 5-10 parts, water-based epoxy resin 10-15 parts, deionized water 60-90 parts.

3. The method for preparing the environmentally friendly 3D printed stereoscopic surface floor according to claim 2, characterized in that: The lamination process described in S2 uses formaldehyde-free soybean protein adhesive for interlayer bonding. The amount of soybean protein adhesive applied is 0.3-0.8 g / m². After being applied between adjacent layers, it is compacted by hot press rollers at 120-140℃ and 1.2-1.8 MPa to ensure that the interlayer bonding strength is ≥2.0 MPa. The adhesive does not delaminate after a 168-hour boiling water test.

4. The method for preparing the environmentally friendly 3D printed stereoscopic surface floor according to claim 3, characterized in that: The three-dimensional surface texture described in S3 is generated through the following steps: P1 uses a 3D scanner to scan physical objects with natural wood grain, stone grain, or custom patterns provided by customers, or creates parametric textures through AI generation algorithms; P2 uses texture optimization software for high-precision processing to create vector texture files with a resolution of ≥600dpi, supporting UV printing adaptation; The P3 uses a multi-nozzle 3D printing system to simultaneously print textures and varnish layers on the substrate surface, achieving 3D texture molding with a precision of 0.1mm.

5. The method for preparing the environmentally friendly 3D printed stereoscopic surface floor according to claim 4, characterized in that: The protective paint layer in S3 adopts a three-layer composite structure: The inner layer is a water-based polyurethane wear-resistant layer (coating amount 15-25g / m²), the middle layer is a self-cleaning layer containing nano-titanium dioxide (coating amount 8-12g / m²), and the outer layer is a fluorocarbon resin anti-fouling layer (coating amount 5-8g / m²). The total VOC content is ≤30g / L.

6. The method for preparing the environmentally friendly 3D printed stereoscopic surface floor according to claim 5, characterized in that: The edge sealing in S4 uses bio-based hot melt adhesive edge sealing technology: The long side uses bamboo fiber reinforced thermoplastic starch (TPS) edge sealing strip, and the short side uses biodegradable polylactic acid (PLA) edge sealing strip. The edge sealing temperature is controlled at 180-200℃, the edge sealing thickness is 1.2-1.8mm, the edge sealing strength is ≥1.5MPa, and the edge sealing material is guaranteed to have a degradation rate of ≥90% under industrial composting conditions for 6 months.

7. The method for preparing the environmentally friendly 3D printed stereoscopic surface floor according to claim 6, characterized in that: The substrate has an intelligent moisture-regulating layer on its back. The moisture-regulating layer is composed of a breathable membrane containing diatomaceous earth / activated carbon composite particles. The moisture absorption per unit area is ≥150g / m². It can maintain the moisture content of the substrate at 8-12% in an environment with 85% humidity, which meets the JISA1408 moisture-proof standard.

8. The method for preparing the environmentally friendly 3D printed stereoscopic surface floor according to claim 7, characterized in that: The test steps in S4 include: M1 Environmental Performance Test: Total volatile organic compounds (TVOC) were ≤0.3mg / m³, and heavy metal content met the CPSC child product safety standards. M2 Durability Test: The abrasion resistance was tested using a Taber abrasion tester with a rotation speed of ≥8000 revolutions, and no cracks were found in the drop ball impact test (1kg hammer, 1m height). M3 dimensional stability test: After 20 thermal cycles under a temperature difference of -20℃ to 80℃, the linear deformation rate is ≤0.2%.

9. The method for preparing the environmentally friendly 3D printed stereoscopic surface floor according to claim 8, characterized in that: The production process of the computer-generated 3D model of the floor in S1 is realized through an Internet of Things (IoT) intelligent system: Q1 Customers upload texture design files via a mobile app, and the system automatically performs 3D modeling and printability analysis; The Q23D printer cluster receives instructions via 5G network and automatically switches printing modules for different materials, enabling the production of more than 5 different textures per day. The Q3 inventory management system uses RFID to track base material inventory and dynamically replenishes stock according to order demand, with an inventory turnover rate of ≤25 days.

10. The method for preparing the environmentally friendly 3D printed stereoscopic surface floor according to claim 9, characterized in that: The raw materials in S2 are traceable to sustainable sources and can be recycled in a closed loop through mechanical recycling or chemical degradation after disposal.

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