Production process of new material for paper decoration

Abstract

The invention discloses a production process of a new material for paper decoration, and relates to the technical field of decoration material production, the dependence on natural mineral products is abandoned, renewable plant fiber paper is adopted as a core base material, the radioactive risk of a raw material source is eliminated, and the environmental safety of long-term indoor use of the material is ensured; in order to solve the problems that paper is insufficient in strength and poor in weather resistance, a composite modifier containing waterborne polyurethane resin and nano silicon dioxide is designed, the modifier fully permeates into the interior and gaps of a paper fiber network through an ultrasonic-assisted impregnation technology, and in the subsequent drying and hot pressing process, the strength of the paper is greatly improved. The resin is crosslinked and has a synergistic effect with the nanoparticles, a compact organic-inorganic hybrid protection layer is formed on the surfaces of the fibers and among the fibers, and the protection layer obviously enhances the mechanical strength, wear resistance and moisture resistance of the paper, so that the paper meets the use requirements of decorative plane materials, and meanwhile, unification of safety and economical efficiency is realized.

Description

Technical Field

[0001] This invention relates to the field of decorative material production technology, specifically to a production process for a new paper-based decorative material. Background Technology

[0002] Currently, in the furniture, architectural interiors, and high-end packaging sectors, there is a growing demand for ultra-thin decorative materials that combine aesthetics and functionality. Existing technology has long been dominated by ultra-thin natural stone, which is produced into thin slabs through physical cutting processes for surface veneer. These materials, with their unique natural textures and feel, are widely used in background walls, cabinet doors, and gift packaging.

[0003] However, existing technologies, such as ultra-thin stone materials, have inherent drawbacks: In terms of raw materials and costs, it relies on mineral resources. The mining, transportation, and complex slicing and grinding processes consume a lot of energy and manpower, resulting in high raw material and manufacturing costs.

[0004] In terms of safety and environmental protection, some natural stone veins contain trace amounts of radioactive elements, and the radon gas they release may pose long-term health risks to the indoor environment, limiting their application in sensitive settings such as bedrooms and children's rooms.

[0005] In terms of physical and construction performance, the inherent brittleness of stone is amplified when the thickness is reduced to the millimeter level, making the product extremely prone to irreversible cracking or chipping due to uneven stress during transportation, cutting and installation.

[0006] In summary, existing ultra-thin stone decorative materials have significant shortcomings in terms of cost control, environmental safety, and physical performance adaptability. Therefore, there is an urgent need in this field for a new type of ultra-thin decorative material that can fundamentally eliminate dependence on mineral raw materials, possess inherent safety properties, and simultaneously exhibit excellent flexibility and shape adaptability, along with its efficient and low-cost preparation process. Summary of the Invention

[0007] The purpose of this invention is to overcome the shortcomings of existing technologies and provide a new production process for paper-based decorative materials. This process eliminates reliance on natural minerals and instead uses renewable plant fiber paper as the core substrate, thus eliminating the radioactive risks of raw material sources and ensuring the environmental safety of the material for long-term indoor use. Addressing the issues of insufficient paper strength and poor weather resistance, this invention designs a composite modifier comprising water-based polyurethane resin and nano-silica. This modifier, through an ultrasonic-assisted impregnation process, fully penetrates into the interior and gaps of the paper fiber network. During subsequent drying and hot pressing, the resin undergoes cross-linking and synergistic action with the nanoparticles, forming a dense organic-inorganic hybrid protective layer on and between the fiber surfaces. This protective layer not only significantly enhances the mechanical strength, abrasion resistance, and moisture resistance of the paper, meeting the requirements for decorative surface materials, but also allows low-cost, readily available paper-based materials to replace expensive stone, fundamentally restructuring the product's cost structure and achieving a balance between safety and economy.

[0008] To solve the above-mentioned technical problems, the present invention provides the following technical solution: a production process for a new paper-based decorative material, the specific steps of which are as follows: S100. Raw material screening and pretreatment: Select plant fiber paper, cut it into paper blanks of a preset size, and place the paper blanks in a constant temperature and humidity environment for pretreatment to remove excess moisture and fix fiber stability. S200 Modification treatment: The pretreated paper blank is immersed in the modifier solution, and ultrasonic vibration is used to assist the penetration. Then it is dried to obtain the modified paper blank. S300, Multi-layer composite molding: The modified paper blanks are stacked in a molding mold and composite-shaped under heating and pressure to obtain an ultra-thin substrate; S400, Light Transmittance and Toughness Enhancement Treatment: The ultra-thin substrate is UV cured and then subjected to low-temperature tempering treatment to improve light transmittance and enhance toughness. S500, Surface Finishing and Cutting: The reinforced substrate is coated and textured, and finally cut to the finished size.

[0009] Furthermore, in S100, the plant fiber paper is bamboo pulp paper or wood pulp paper, the temperature of the constant temperature and humidity environment is 25-30℃, the humidity is 40-50%, and the pretreatment time is 2-3 hours.

[0010] Furthermore, in step S200, the modifier solution is composed of waterborne polyurethane resin, silica nanoparticles, and silane coupling agent KH-550 mixed in a mass ratio of 80:15:5, and diluted with deionized water to a concentration of 10-15%. The ultrasonic vibration is used to promote the penetration and filling of the modifier solution into the gaps between the paper blank fibers. The silica nanoparticles are used to enhance the hardness and abrasion resistance of the new paper decorative material, and the silane coupling agent KH-550 is used to improve the interfacial bonding force between the waterborne polyurethane resin, the plant fiber paper, and the silica nanoparticles.

[0011] Furthermore, the ultrasonic oscillation frequency is 20-30kHz, the soaking time is 30-40 minutes, the drying temperature is 60-70℃, and the drying time is 1-1.5 hours.

[0012] Furthermore, in S300, the molding die used for multi-layer composite molding is an upper and lower die structure. The lower die of the molding die is provided with a heating channel for heating the mold cavity. The upper die of the molding die is provided with a pressure regulating device for controlling the mold closing pressure. The surface of the mold cavity of the molding die is provided with anti-slip texture to prevent the modified paper blank from sliding during hot pressing and to transfer the texture to the surface of the ultra-thin substrate.

[0013] Furthermore, the process parameters for the multi-layer composite molding are as follows: mold temperature 80-90℃, preheating for 5 minutes and then applying pressure, with a pressure range of 0.3-0.5MPa, and maintaining constant temperature and pressure for 20-30 minutes; The thickness of the ultrathin substrate is controlled at 0.6 mm ± 0.05 mm.

[0014] Furthermore, in the S400, the ultraviolet curing uses an ultraviolet light source with a wavelength of 365nm and an irradiation time of 15-20 minutes. The low-temperature tempering process involves placing the substrate in a constant temperature furnace at 40-50°C for 2 hours and then cooling it to room temperature. The ultraviolet irradiation can stimulate the waterborne polyurethane resin in the modifier solution to undergo a cross-linking and curing reaction, thereby forming a three-dimensional network structure to improve the light transmittance of the ultrathin substrate. The low-temperature tempering treatment is used to eliminate the internal stress generated in the ultra-thin substrate during hot pressing and UV curing, thereby significantly improving its toughness and bending performance.

[0015] Furthermore, in S500, the surface finishing includes coating with a transparent wear-resistant coating or printing a decorative texture; The transparent wear-resistant coating is a polycarbonate coating, used to enhance the surface wear resistance and scratch resistance of the finished paper decorative material.

[0016] Furthermore, the new paper-based decorative material can be applied to furniture board veneers, wall decorations, floor decorations, or outer packaging boxes. This new paper-based decorative material has a thickness of 0.6 mm, a light transmittance of ≥85%, a bending radius of ≥5 cm, is non-radioactive, and has the characteristics of being bendable, compositeable, and shapeable.

[0017] Compared with existing technologies, the production process of this new paper-based decorative material has the following advantages: I. This invention eliminates the reliance on natural minerals and instead uses renewable plant fiber paper as the core substrate, thus eliminating the radioactive risks of raw material sources and ensuring the environmental safety of the material for long-term indoor use. Addressing the issues of insufficient paper strength and poor weather resistance, this invention designs a composite modifier comprising water-based polyurethane resin and nano-silica. This modifier, through an ultrasonic-assisted impregnation process, fully penetrates into the paper fiber network and its gaps. During subsequent drying and hot pressing, the resin undergoes cross-linking and synergistic action with the nanoparticles, forming a dense organic-inorganic hybrid protective layer on and between the fibers. This protective layer not only significantly enhances the paper's mechanical strength, abrasion resistance, and moisture resistance, meeting the requirements for decorative surface materials, but also allows low-cost, readily available paper-based materials to replace expensive stone, fundamentally restructuring the product's cost structure and achieving a balance between safety and economy.

[0018] II. This invention utilizes a strengthening process combining ultraviolet curing and low-temperature tempering to regulate the final properties of the material at the molecular level. During the ultraviolet curing stage, ultraviolet light excites the resin matrix in the modifier to undergo a rapid and deep cross-linking reaction, forming a highly uniform and transparent three-dimensional network structure. This greatly reduces the light scattering points inside the material, achieving high light transmittance. In the subsequent low-temperature tempering process, the internal stress generated by rapid curing is slowly released, and the molecular chain segments gain a certain degree of mobility for rearrangement. This significantly improves the material's ductility and flexibility while maintaining its hardness and transparency after curing. This characteristic allows the material to perfectly fit various curved surfaces and irregularly shaped substrates, solving the fatal flaw of ultra-thin stone being absolutely brittle and unable to bend, and expanding its application possibilities in complex three-dimensional scenarios such as curved walls, column packaging, and streamlined furniture.

[0019] Other advantages, objectives and features of the invention will be set forth in part in the description which follows, and in part will be apparent to those skilled in the art from the following examination or study, or may be learned from the practice of the invention. Attached Figure Description

[0020] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the accompanying drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are merely some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without any creative effort.

[0021] Figure 1 This is a flowchart illustrating the production process of a new paper-based decorative material. Detailed Implementation

[0022] To further illustrate the technical means and effects of the present invention in achieving its intended purpose, the following detailed description of the specific implementation methods, structures, features, and effects of the present invention, in conjunction with the accompanying drawings and preferred embodiments, is provided below.

[0023] To address the shortcomings of existing ultra-thin decorative materials, such as reliance on mineral resources, high costs, radioactive safety hazards, and inability to adapt to complex shapes, this invention provides a new production process for paper-based decorative materials. The process, encompassing pretreatment of plant fiber paper substrates, infiltration of composite modifiers, multi-layer hot-pressing, UV curing and low-temperature tempering, and surface finishing, aims to achieve a synergistic balance of environmental safety, low cost, high light transmittance, and excellent flexibility. This invention is primarily applicable to decorative applications such as furniture panel veneers, wall decorations, floor decorations, and outer packaging boxes. In these applications, material safety, environmental friendliness, shape adaptability, and cost-effectiveness are crucial for enhancing decorative effects and user experience. Traditional ultra-thin stone decorative materials cannot simultaneously address raw material sustainability, physical property compatibility, and cost control, resulting in limited application scenarios, significant construction losses, and an inability to meet diverse decorative needs.

[0024] This invention, by constructing a complete production chain from substrate modification and composite molding to performance enhancement, creates a new paper-based decorative material system with high efficiency and balanced performance, achieving a comprehensive upgrade from basic decorative functions to multi-functional integration including safety, flexibility, and light transmission. Specifically, for example... Figure 1 As shown, the specific steps of the production process of a new paper-based decorative material of the present invention are as follows: S100. Raw material screening and pretreatment: Select plant fiber paper, cut it into paper blanks of a preset size, and place the paper blanks in a constant temperature and humidity environment for pretreatment to remove excess moisture and fix fiber stability. S200 Modification treatment: The pretreated paper blank is immersed in the modifier solution, and ultrasonic vibration is used to assist the penetration. Then it is dried to obtain the modified paper blank. S300, Multi-layer composite molding: The modified paper blanks are stacked in a molding mold and composite-shaped under heating and pressure to obtain an ultra-thin substrate; S400, Light Transmittance and Toughness Enhancement Treatment: The ultra-thin substrate is UV cured and then subjected to low-temperature tempering treatment to improve light transmittance and enhance toughness. S500, Surface Finishing and Cutting: The reinforced substrate is coated and textured, and finally cut to the finished size.

[0025] In S200, the modifier solution is prepared by mixing waterborne polyurethane resin, silica nanoparticles, and silane coupling agent KH-550 in a mass ratio of 80:15:5, and diluted with deionized water to a concentration of 10-15%. The ultrasonic vibration promotes the penetration and filling of the modifier solution into the gaps between the paper fibers. The silica nanoparticles enhance the hardness and abrasion resistance of the new paper decorative material, and the silane coupling agent KH-550 improves the interfacial bonding between the waterborne polyurethane resin, the plant fiber paper, and the silica nanoparticles. The ultrasonic vibration frequency is 20-30 kHz, the soaking time is 30-40 minutes, the drying temperature is 60-70℃, and the drying time is 1-1.5 hours. In S300, the molding die used for multi-layer composite molding has an upper and lower die structure. The lower die of the molding die has a heating channel inside for heating the mold cavity, and the upper die of the molding die has a pressure regulating device for controlling the mold closing pressure. The surface of the mold cavity of the molding die has an anti-slip texture to prevent the modified paper blank from sliding during hot pressing and to transfer the texture to the surface of the ultra-thin substrate. The process parameters for multi-layer composite molding are: mold temperature 80-90℃, preheating for 5 minutes, applying pressure, pressure range of 0.3-0.5MPa, and maintaining constant temperature and pressure for 20-30 minutes; the thickness of the ultra-thin substrate is controlled at 0.6mm ± 0.05mm. In S400, ultraviolet curing uses a 365nm ultraviolet light source for 15-20 minutes. Low-temperature tempering involves placing the substrate in a constant-temperature oven at 40-50℃ for 2 hours, followed by cooling to room temperature. The ultraviolet irradiation excites the waterborne polyurethane resin in the modifier solution to undergo a cross-linking and curing reaction, forming a three-dimensional network structure to improve the light transmittance of the ultrathin substrate. The low-temperature tempering eliminates the internal stress generated during hot pressing and ultraviolet curing, significantly improving its toughness and bending properties. In S500, surface finishing includes coating with a transparent abrasion-resistant coating or printing decorative textures. The transparent abrasion-resistant coating is a polycarbonate coating used to enhance the surface abrasion resistance and scratch resistance of the finished paper-based decorative material.

[0026] To make the objectives and technical solutions of this invention clearer, the invention will be further described in detail below with reference to specific embodiments. It should be understood that the specific embodiments described herein are for illustrative purposes only and are not intended to limit the scope of protection of this invention.

[0027] Performance Testing Specifications The performance tests of the new paper-based decorative materials involved in each embodiment of the present invention were all performed according to the following methods to ensure the accuracy and comparability of the test results: Thickness test: Using a digital micrometer with an accuracy of 0.001mm, five test points were selected at different locations on the finished product, and the average value was taken as the final thickness data. Transmittance test: Using a visible spectrophotometer with visible light at a wavelength of 550nm as the test light source, four test areas were selected at the center and around the finished product, and the average value of the test results was taken. Bending performance test: The finished product is bent to one side at a constant rate using a room temperature bending test method, and the minimum bending radius without cracking or white marks is recorded. Surface hardness test: According to the pencil hardness test standard, a 2H pencil was used to conduct a scratch test under a load of 500g, and the surface was observed to see if scratches appeared. Abrasion resistance test: Using a Martindale abrasion tester, under conditions of 12 kPa pressure and 1000 friction cycles, the surface wear was observed after the test to evaluate the abrasion resistance level; Radioactivity testing: Low-background multichannel gamma spectrometer was used for detection, and the internal exposure index (Ira) and external exposure index (Ir) were recorded.

[0028] Example 1 This embodiment uses bamboo pulp paper as raw material and prepares a new type of general-purpose paper decorative material with balanced performance through a standard process flow of raw material pretreatment, ultrasonic-assisted impregnation with composite modifier, multi-layer hot pressing, ultraviolet curing and low-temperature tempering strengthening, and surface wear-resistant coating. This embodiment aims to demonstrate the stable production process and benchmark performance of the present invention under optimized raw materials and typical process parameters, and provide a reference for subsequent process adjustment and scenario adaptation.

[0029] Specific implementation process Raw material selection and pretreatment: High-quality bamboo pulp paper is selected as the core substrate. The bamboo pulp paper is cut into paper blanks of a preset size of 50cm×50cm using precision cutting equipment. The paper blanks are then placed in a constant temperature and humidity chamber for pretreatment. The temperature of the constant temperature and humidity environment is set at 28℃ and the humidity at 45%. The pretreatment time is controlled at 2.5 hours. This process removes excess moisture from the paper blanks and fixes the stability of the fiber structure to avoid fiber shrinkage or deformation during subsequent processing.

[0030] Modification Treatment: First, a modifier solution is prepared. Waterborne polyurethane resin, silica nanoparticles, and silane coupling agent KH-550 are accurately weighed according to a mass ratio of 80:15:5. After mixing thoroughly, an appropriate amount of deionized water is added for dilution, resulting in a 12% concentration modifier solution. The pretreated bamboo pulp paper blank is then completely immersed in this modifier solution. An ultrasonic vibration device is activated, and the vibration frequency is set to 25kHz. Immersion continues for 35 minutes, utilizing the cavitation effect and vibration of ultrasound to promote the full penetration of the modifier solution into the gaps and interior of the paper blank fibers. After immersion, the paper blank is removed and placed in a drying oven. The drying temperature is set to 65℃, and the drying time is 1.2 hours, until the paper blank is completely dry, yielding the modified paper blank. Silica nanoparticles enhance the material's hardness and wear resistance, while the silane coupling agent KH-550 improves the interfacial bonding force between the waterborne polyurethane resin, bamboo pulp paper fibers, and silica nanoparticles, ensuring stable modification results.

[0031] Multi-layer composite molding: Four layers of prepared modified paper blanks are neatly stacked in a molding die with an upper and lower mold structure. The lower mold has a heating channel inside, and the upper mold is equipped with a pressure regulating device. The mold cavity surface has an anti-slip texture. The mold heating system is activated, raising the mold temperature to 85℃. After preheating for 5 minutes, a mold closing pressure of 0.4MPa is applied through the pressure regulating device, maintaining a constant temperature and pressure for 25 minutes. During the hot pressing process, the anti-slip texture on the mold cavity surface prevents the modified paper blanks from sliding and simultaneously transfers the texture to the substrate surface, ultimately obtaining an ultra-thin substrate with a thickness of 0.6mm.

[0032] Light transmittance and toughness enhancement treatment: The ultra-thin substrate is transferred to a UV curing device and irradiated with a 365nm UV light source for 18 minutes. UV irradiation excites the waterborne polyurethane resin in the modifier to undergo a cross-linking and curing reaction, forming a uniform and transparent three-dimensional network structure, reducing internal light scattering points and improving light transmittance. After UV curing, the substrate is placed in a constant temperature oven for low-temperature tempering. The oven temperature is set at 45℃, and after holding at this temperature for 2 hours, it is naturally cooled to room temperature. This low-temperature tempering process effectively eliminates the internal stress generated in the substrate during hot pressing and UV curing, significantly improving the material's toughness and bending properties.

[0033] Surface finishing and cutting: The reinforced substrate is surface finished by uniformly applying a transparent, wear-resistant polycarbonate coating using a spraying process. This coating enhances the surface wear resistance and scratch resistance of the finished product. After the coating has fully cured, the substrate is cut into finished products of the corresponding specifications using precision cutting equipment according to the actual size requirements of the wall decoration.

[0034] In summary, the new paper-based decorative material prepared in this embodiment has the following performance test results: a thickness of 0.60 mm, a light transmittance of 86.3%, a minimum bending radius of 4.8 cm, a surface pencil hardness of 2H, no obvious wear marks on the surface after 1000 cycles of Martindale abrasion resistance test, an abrasion resistance level ≥3, an internal irradiance index (Ira) <0.1, and an external irradiance index (Ir) <0.1, meeting the performance requirements of general decorative scenarios.

[0035] The new paper-based decorative material prepared in this embodiment is mainly used in wall decoration scenarios. It can be directly adhered to the wall base or used in combination with other substrates. It has a smooth appearance, natural texture, and good light transmittance and flexibility. No complicated process is required during installation, and it will not crack or chip due to cutting or transportation. It provides a high-performance and low-cost new material option for general decoration scenarios.

[0036] Example 2 This embodiment uses wood pulp paper as raw material. By reducing the amount of raw materials used, shortening the processing time, and reducing energy consumption, the production efficiency and cost structure are optimized. This embodiment aims to demonstrate the wide adaptability and flexible adjustment space of the process of this invention, and to provide a solution for large-scale production that pursues economic efficiency.

[0037] Specific implementation process Raw material selection and pretreatment: Wood pulp paper is selected as the base material. Wood pulp paper has good fiber toughness and is suitable for batch processing. The wood pulp paper is cut into small paper blanks of 30cm×30cm by an automatic cutting machine, which makes it easier to process quickly and in batches. Then the paper blanks are placed in a constant temperature and humidity chamber. The pretreatment parameters are set as follows: temperature 25℃, humidity 40%, and pretreatment time 2 hours. While ensuring the removal of excess moisture from the paper blanks and stabilizing the fiber structure, the pretreatment cycle is shortened to the maximum extent and the production efficiency is improved.

[0038] Modification treatment: A mixture of waterborne polyurethane resin, silica nanoparticles, and silane coupling agent KH-550 was prepared according to the same mass ratio as in Example 1 (80:15:5). Deionized water was added to dilute the mixture to a 10% modifier solution. The pretreated wood pulp blank was then immersed in this solution. An ultrasonic vibration device was started, setting the vibration frequency to 20 kHz and the immersion time to 30 minutes. After immersion, the blank was placed in a drying oven, and the drying temperature was set to 60°C for 1 hour to quickly remove moisture, resulting in modified wood pulp blank. This process, by reducing the modifier concentration and shortening the immersion and drying times, reduces raw material and energy consumption, thereby lowering production costs while ensuring the modification effect meets standards.

[0039] Multi-layer composite molding: Three layers of modified wood pulp paper blanks are stacked in a molding die with the same structure as in Example 1, reducing the number of paper blank layers to decrease raw material consumption and hot pressing time. The die heating system is activated, raising the die temperature to 80°C. After preheating for 5 minutes, a mold closing pressure of 0.3 MPa is applied, and the temperature and pressure are maintained at a constant level for 20 minutes. During the hot pressing process, the anti-slip texture of the die cavity effectively prevents the paper blanks from sliding and transfers the texture, ultimately resulting in an ultra-thin substrate with a thickness of 0.58 mm.

[0040] Light transmittance and toughness enhancement treatment: The ultra-thin substrate is fed into a UV curing device and irradiated with a 365nm wavelength UV light source for 15 minutes to ensure that the waterborne polyurethane resin is fully cross-linked and cured, forming a three-dimensional network structure to ensure light transmittance. After UV curing, the substrate is placed in a constant temperature oven, and the low-temperature tempering temperature is set to 40℃. After holding at this temperature for 2 hours, it is cooled to room temperature to effectively release the internal stress of the substrate and ensure that the bending performance meets the standards.

[0041] Surface finishing and cutting: The reinforced substrate is finished with a printing process. Wood grain decorative texture is selected for printing. After printing, the substrate is cut into the corresponding finished size according to the specifications and dimensions of the furniture board to complete the production.

[0042] The new paper-based decorative material prepared in this embodiment has the following performance test results: thickness of 0.58mm, light transmittance of 85.1%, minimum bending radius of 5.0cm, surface pencil hardness of 2H, no obvious scratches on the surface after 1000 cycles of Martindale abrasion test (abrasion resistance level ≥2), internal radiation index (Ira) <0.1, external radiation index (Ir) <0.1, and no radioactive risk. While meeting the basic requirements for furniture board veneer, it has the advantages of high production efficiency and controllable cost.

[0043] In summary, the new paper-based decorative material prepared in this embodiment is mainly used in furniture panel veneer applications. It can be directly bonded to the surface of furniture substrates such as solid wood boards and MDF, replacing traditional decorative panels. It exhibits a natural wood grain texture, is easy to install, and is not easily damaged during transportation and cutting, meeting the mass production needs of furniture manufacturing.

[0044] Example 3 This embodiment focuses on improving the high light transmittance performance of light-transmitting decorative panels for specific application scenarios of lighting fixtures. By optimizing ultraviolet curing parameters, enhancing the penetration effect of modifiers, and selecting high light transmittance surface coatings, the standard process is specifically adjusted. This embodiment aims to demonstrate the customizability of the present invention and prove that by fine-tuning the process, the material can meet differentiated application needs while maintaining its core performance, thus expanding the application range of the material.

[0045] In the field of lighting decoration, translucent decorative panels need to possess good light transmittance, decorative appeal, and safety. Traditional translucent decorative materials either have insufficient light transmittance, pose a risk of radioactivity, or are easily damaged due to poor toughness. This embodiment, through process optimization, prepares a new paper-based decorative material that is highly transparent, radiation-free, and flexible, thus meeting the usage requirements of translucent decorative panels for lighting fixtures.

[0046] Raw material selection and pretreatment: High-purity bamboo pulp paper was selected as the base material. This bamboo pulp paper has high fiber purity and few impurities, which reduces light obstruction and scattering, laying the foundation for high light transmittance. The bamboo pulp paper was cut into 40cm×40cm paper blanks and placed in a constant temperature and humidity chamber. The temperature was set at 29℃, the humidity at 48%, and the pretreatment time at 2.8 hours to ensure that the paper blank fibers were fully expanded, creating conditions for the uniform penetration of the subsequent modifier.

[0047] Modification Treatment: A mixture of waterborne polyurethane resin, silica nanoparticles, and silane coupling agent KH-550 was prepared at a mass ratio of 80:15:5. Deionized water was added to dilute the mixture to a 14% modifier solution. This higher concentration ensures a sufficiently thick modified layer forms on the fiber surface without affecting light transmittance. The pretreated paper blank was then immersed in the modifier solution. An ultrasonic vibration device was activated, and the vibration frequency was set to 28 kHz for 38 minutes. The solution was stirred every 10 minutes during immersion to ensure uniform concentration and promote thorough penetration of the modifier into the fiber interior and interstices, preventing uneven penetration that could lead to differences in light transmittance. After immersion, the paper blank was placed in a drying oven. The drying temperature was set to 68℃ for 1.4 hours, using a gradient heating method. The initial temperature was 40℃, increasing by 14℃ every 30 minutes to 68℃. This prevented rapid drying from causing the modifier to accumulate on the fiber surface, which would affect light transmittance. The final product was a modified paper blank.

[0048] Multi-layer composite molding: Four layers of modified paper blanks are selected and neatly stacked in the molding die, ensuring no air bubbles or misalignment between the blanks. The die heating system is activated, raising the die temperature to 88℃. After preheating for 5 minutes, a closing pressure of 0.45MPa is applied, and the temperature and pressure are maintained at a constant level for 28 minutes. Extending the hot-pressing time ensures full composite of the multi-layer paper blanks, reduces interlayer gaps, and prevents light scattering between layers. The die cavity surface is finished with a smooth, non-slip texture to prevent the paper blanks from sliding while avoiding excessively deep textures that could affect light transmittance. The final product is an ultra-thin substrate with a thickness of 0.61mm, and the thickness uniformity is controlled within ±0.02mm.

[0049] Light transmittance and toughness enhancement treatment: The ultra-thin substrate is transferred to a UV curing device using a high-power UV light source with a wavelength of 365nm. The irradiation time is extended to 20 minutes. Extending the irradiation time ensures a more complete cross-linking and curing reaction of the waterborne polyurethane resin, forming a denser and more uniform three-dimensional network structure. This minimizes light scattering points within the material and improves light transmittance. After UV curing, the substrate is placed in a constant-temperature oven for low-temperature tempering. The oven temperature is set at 48℃ and held for 2 hours. Then, the temperature is reduced from 48℃ to room temperature at 5℃ per hour to release internal stress and prevent residual stress caused by rapid cooling. This process maintains good toughness and bending performance while ensuring high light transmittance.

[0050] Surface Finishing and Cutting: A specific type of polyurethane coating with high light transmittance is selected as the surface finishing material. This coating has a light transmittance of ≥95% and possesses good wear resistance and weather resistance. It is uniformly coated onto the substrate surface using a roller coating process, with the coating thickness controlled at 0.03mm to ensure that the coating does not affect light transmittance while enhancing the surface's wear and scratch resistance. After the coating has fully cured, it is precisely cut using laser cutting equipment according to the design dimensions of the lamp panel to obtain the finished light-transmitting decorative panel.

[0051] The new paper-based decorative material prepared in this embodiment has the following performance test results: a thickness of 0.61 mm, a light transmittance of 89.2%, a minimum bending radius of 4.5 cm, a surface pencil hardness of 2H, no surface wear after 1000 cycles of Martindale abrasion test (abrasion resistance level ≥ 3), an internal irradiance index (Ira) < 0.1, an external irradiance index (Ir) < 0.1, and no radioactive hazards, thus meeting the high light transmittance requirements of light-transmitting decorative panels for lamps.

[0052] The new paper-based decorative material prepared in this embodiment is mainly used in light-transmitting decorative panels for lamps. It can be installed on the surface of various lamps such as chandeliers, wall lamps, and light boxes. It has both decorative and light-transmitting properties. The light passes through the panel in a soft and uniform manner without obvious shadows. Moreover, the material is non-radioactive and safe and environmentally friendly to use.

[0053] To visually demonstrate the core performance of the new paper-based decorative material of this invention under different process parameters and raw material selections, the performance test results of Examples 1, 2, and 3 are summarized in the table below:

[0054] As can be seen from the table of performance test results above, the finished products of the three embodiments all meet the core requirements of thickness control within the range of 0.6mm±0.05mm, light transmittance ≥85%, minimum bending radius ≥4.5cm, and surface pencil hardness of 2H. Moreover, none of them have radioactive hazards, which solves the safety hazards of traditional ultra-thin stone decorative materials and achieves the unity of environmental protection and practicality. The process is compatible with a variety of renewable plant fiber paper raw materials such as bamboo pulp paper and wood pulp paper. The raw material cost is low and easy to obtain. Compared with ultra-thin stone that relies on mineral resources, it reduces the production cost from the source and avoids the high energy consumption problem in the mining and processing process.

[0055] In summary, by constructing a complete production chain from substrate pretreatment, modification and composite to performance enhancement, this invention can not only replace traditional ultra-thin stone materials for general decorative applications, but also adapt to special needs such as high-efficiency production and high light transmittance through process fine-tuning, thus expanding the application boundaries of paper-based decorative materials and providing diverse material options for furniture decoration, architectural interiors, high-end packaging and other fields.

[0056] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art can make some modifications or alterations to the above-disclosed technical content to create equivalent embodiments without departing from the scope of the present invention. Any simple modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present invention without departing from the scope of the present invention shall still fall within the scope of the present invention.

Claims

1. A production process for a new paper-based decorative material, characterized in that, The specific steps of this preparation process are as follows: S100. Raw material screening and pretreatment: Select plant fiber paper, cut it into paper blanks of a preset size, and place the paper blanks in a constant temperature and humidity environment for pretreatment to remove excess moisture and fix fiber stability. S200 Modification treatment: The pretreated paper blank is immersed in the modifier solution, and ultrasonic vibration is used to assist the penetration. Then it is dried to obtain the modified paper blank. S300, Multi-layer composite molding: The modified paper blanks are stacked in a molding mold and composite-shaped under heating and pressure to obtain an ultra-thin substrate; S400, Light Transmittance and Toughness Enhancement Treatment: The ultra-thin substrate is UV cured and then subjected to low-temperature tempering treatment to improve light transmittance and enhance toughness. S500, Surface Finishing and Cutting: The reinforced substrate is coated and textured, and finally cut to the finished size.

2. The production process of a new paper-based decorative material according to claim 1, characterized in that, In step S100, the plant fiber paper is bamboo pulp paper or wood pulp paper, the temperature of the constant temperature and humidity environment is 25-30℃, the humidity is 40-50%, and the pretreatment time is 2-3 hours.

3. The production process of a new paper-based decorative material according to claim 1, characterized in that, In S200, the modifier solution is composed of waterborne polyurethane resin, silica nanoparticles and silane coupling agent KH-550 mixed in a mass ratio of 80:15:5, and diluted with deionized water to a concentration of 10-15%.

4. The production process of a new paper-based decorative material according to claim 1, characterized in that, The ultrasonic oscillation frequency is 20-30kHz, the soaking time is 30-40 minutes, the drying temperature is 60-70℃, and the drying time is 1-1.5 hours.

5. The production process of a new paper-based decorative material according to claim 1, characterized in that, In S300, the molding die used for multi-layer composite molding is an upper and lower die structure. The lower die of the molding die is provided with a heating channel for heating the mold cavity. The upper die of the molding die is provided with a pressure regulating device for controlling the mold closing pressure. The surface of the mold cavity of the molding die is provided with anti-slip texture to prevent the modified paper blank from sliding during hot pressing and to transfer the texture to the surface of the ultra-thin substrate.

6. The production process of a new paper-based decorative material according to claim 5, characterized in that, The process parameters for the multi-layer composite molding are as follows: mold temperature 80-90℃, preheating for 5 minutes and then applying pressure, with a pressure range of 0.3-0.5MPa, and maintaining constant temperature and pressure for 20-30 minutes; The thickness of the ultrathin substrate is controlled at 0.6 mm ± 0.05 mm.

7. The production process of a new paper-based decorative material according to claim 1, characterized in that, In the S400, the ultraviolet curing uses an ultraviolet light source with a wavelength of 365nm and the irradiation time is 15-20 minutes. The low-temperature tempering process involves placing the substrate in a constant-temperature furnace at 40-50°C for 2 hours and then cooling it to room temperature.

8. The production process of a new paper-based decorative material according to claim 1, characterized in that, In S500, surface modification includes coating a transparent wear-resistant coating or printing a decorative texture; The transparent wear-resistant coating is a polycarbonate coating.

9. The production process of a new paper-based decorative material according to claim 1, characterized in that, The new paper-based decorative material can be used for furniture panel veneers, wall decorations, floor decorations, or outer packaging boxes.

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