Fiber-based mislaying laminated decorative sheet and manufacturing process thereof

Abstract

The present application relates to a kind of fiber-based mislayered laminated decorative sheet and its manufacturing process, belong to environmental protection decorative material technical field.It is especially related to a kind of fiber-based mislayered laminated decorative sheet and its manufacturing process, which is composed of square plate body and the thin edge of ladder, suspended thin edge extending from plate body outward, thin edge of ladder and suspended thin edge are adjacent arrangement;And the plate body, thin edge of ladder and suspended thin edge are all with polyester fiber and acrylic fiber as base material hot melt cold-pressing forming, by with fiber base material pressing forming fiber-based mislayered laminated decorative sheet with thin edge of ladder and suspended thin edge, so that through the buckling between thin edge of ladder and suspended thin edge can quickly realize assembly, and then simplify installation difficulty, can be applicable to ground, wall and ceiling installation.

Description

Technical Field

[0001] This invention relates to the field of polyester fiber board technology, and in particular to a fiber-based staggered laminated decorative board and its manufacturing process. Background Technology

[0002] Traditional flooring and wall panels are mostly made of PVC, stone-plastic, and wood-plastic materials, which contain halogens, plasticizers, and formaldehyde. They are not recyclable, have poor environmental performance, do not meet global high-end building material environmental standards and green development industry policies, and are prone to causing environmental pollution after being discarded.

[0003] Furthermore, existing decorative panels generally adopt connection and structural designs such as snap-fit, male and female grooves, plug-in, and double-layer composite, which not only have high barriers and are prone to infringement disputes, but also have defects such as complicated installation, easy cracking after long-term use, easy displacement, and large splicing gaps, resulting in limited adaptability.

[0004] Fiber-based materials have traditionally been used only as soft padding layers, and it is difficult to manufacture high-strength rigid structural panels through process optimization. They suffer from poor dimensional stability, inability to achieve seamless installation with staggered layers, and insufficient mechanical properties, which limits their large-scale application in the field of decorative panels.

[0005] Therefore, the market lacks a universal decorative panel technology that can be applied to multiple scenarios such as floors, walls, and ceilings, while also being environmentally friendly, recyclable, easy to install, and structurally stable, to meet the core needs of the high-end building materials market.

[0006] Polyester fiber sound-absorbing decorative panels (often simply called polyester fiber sound-absorbing panels) are a new type of environmentally friendly building material made from 100% polyester fiber (PET) through high-temperature hot-melt pressing. They combine sound absorption and decorative effects. Through a special process, they form a three-dimensional porous structure similar to a cocoon, achieving both density diversity and ensuring good ventilation, making them a leader among sound-absorbing and heat-insulating materials. Compared to traditional flooring and wall panels, polyester fiber sound-absorbing decorative panels have the outstanding characteristics of being environmentally friendly and recyclable.

[0007] For example, Chinese invention patent CN202310392343.6 specifically discloses a conveniently assembled polyester fiber sound-absorbing panel and its manufacturing method. The panel includes a first polyester fiber sound-absorbing panel, a second polyester fiber sound-absorbing panel, and an assembly outer component. Inner inserts are fixedly installed on both sides of the first polyester fiber sound-absorbing panel, with a buckle on one side. A transverse plate is fixedly installed on one side of the first polyester fiber sound-absorbing panel. A limiting groove is formed on one side of the second polyester fiber sound-absorbing panel, with a connector adhered inside the limiting groove. Hooks are fixedly installed on both sides of the connector, and a fastening plate is fixedly installed on the outer wall of the hook. An assembly groove is formed on the outer wall of the fastening plate. The connector has hooks on both sides, and both the first and second polyester fiber sound-absorbing panels are inserted into the assembly outer component. The buckle engages with the hook, and the transverse plate also engages with the assembly groove of the fastening plate. This assembles the first and second polyester fiber sound-absorbing panels into the assembly outer component, facilitating their assembly and disassembly.

[0008] However, in the above technical solutions, the assembly structure of polyester fiber sound-absorbing panels is very complicated. Existing polyester fiber sound-absorbing panels mostly adopt interlocking, male and female grooves, plug-in, and double-layer composite structures, which are prone to cracking, displacement, and complicated installation steps. Summary of the Invention

[0009] To address the above problems, this invention provides a fiber-based staggered laminated decorative panel and its manufacturing process. By directly molding a fiber-based staggered laminated decorative panel with stepped thin edges and suspended thin edges using polyester fiber as the substrate, assembly can be quickly achieved through the interlocking of the stepped thin edges and suspended thin edges, thereby simplifying the installation difficulty of polyester fiber sound-absorbing panels. It can be used for installation on floors, walls, and ceilings, taking into account strength, environmental protection, and molding effect, and explicitly excluding PVC and formaldehyde components.

[0010] To achieve the above objectives, the present invention provides the following technical solution: A fiber-based staggered laminated decorative panel It consists of a square board body and stepped thin edges and suspended thin edges extending outward from the board body, with the stepped thin edges and suspended thin edges arranged adjacent to each other. Furthermore, the main body of the board, the stepped thin edge, and the suspended thin edge are all formed by hot-melting and pressing with fiber filaments as the base material.

[0011] As an improvement, it contains 100 wt% polyester fiber by weight percentage.

[0012] As an improvement, it contains 40-70 wt% polyester fiber and 60-30 wt% polypropylene fiber by weight percentage.

[0013] As an improvement, it contains ≥70 wt% polyester fiber and the remainder is polypropylene fiber.

[0014] As an improvement, it contains 35-75 wt% polyester fiber, 25-65 wt% polypropylene fiber and 0-10 wt% environmentally friendly auxiliary fiber by weight percentage. The environmentally friendly auxiliary fiber is one of bamboo fiber and hemp fiber. The environmentally friendly auxiliary fiber is VOC-free and recyclable, and is used to optimize the toughness or fire resistance of the board.

[0015] In addition, the present invention also provides a process for manufacturing the fiber-based staggered laminated decorative panel described in any of the above claims, the complete molding process being: step a, fiber opening → step b, mixing → step c, carding and web laying → step d, needle punching (can be skipped) → step e, high temperature baking (optional, can be skipped) → step f, cooling (optional, can be skipped, only activated after step e) → step g, heated and cold pressed molding → step h, surface treatment → step i, cutting → finished product (where step a and d are completed on a continuous production line, step ef is an optional step on a continuous production line, step gi is a separate process, and the parameters of each step can be finely adjusted according to the substrate formula).

[0016] This process is suitable for the production of fiber-based staggered laminated decorative panels (suitable for flooring / wall panels / ceilings) based on the above four substrate formulations. It is entirely free of PVC and formaldehyde, balancing product strength, dimensional stability, and the desired thin-edge staggered molding effect. The complete process and detailed instructions are as follows, including the following steps: Step a, Fiber opening (first process in a continuous production line): Operating equipment: Twin-shaft opening machine (equipped with carding rollers and beater rollers, with adjustable speed), integrated at the front end of the continuous production line, seamlessly connected with subsequent mixing processes, and adaptable to the processing of fiber raw materials of different lengths and fineness.

[0017] Raw material requirements: Use dry, impurity-free polyester fibers (length 38-65mm, fineness 1.5-25D) and polypropylene fibers (length 38-65mm, fineness 2.0-25D). Auxiliary fibers (if selected) should be 35-60mm in length and 2.0-20D in fineness. The melting point of polyester fibers should be 255-260℃, and the melting point of polypropylene fibers should be 165-175℃. The moisture content of the raw materials should be ≤8%, and there should be no lumps or oil stains.

[0018] Key operating points: Feed the fiber raw materials of the formula ratio into the opening machine in batches, adjust the speed of the beater roller to 800-1200 r / min and the speed of the carding roller to 300-500 r / min. Through mechanical beating and combing, break up the fiber bundles and make the fibers into loose monofilaments. Remove dust and impurities from the raw materials (impurity screening accuracy ≥98%) to ensure that the fibers are evenly dispersed and free from obvious clumps and lint. The processed loose fibers are directly sent to the next mixing process through the conveyor device to achieve continuous production without manual secondary transfer and avoid secondary fiber agglomeration.

[0019] Process objective: To loosen fiber bundles, laying the foundation for subsequent mixing and web laying, avoiding fiber agglomeration that leads to uneven density and insufficient strength within the board, adapting to the high-efficiency operation requirements of continuous production lines, while ensuring the cleanliness of raw materials and guaranteeing the environmental performance of the product.

[0020] Step b, mixing (second process in a continuous production line): Operating equipment: High-speed mixer (with stirring paddle, adjustable stirring speed and time, and equipped with temperature monitoring device), connected after the fiber opening process, is one of the core equipment of the continuous production line.

[0021] Mixing parameters: stirring speed 500-800 r / min, mixing time 15-25 min, mixing temperature controlled at 0-40℃ (room temperature mixing to avoid premature softening of fibers), mixing uniformity ≥95% (sampling test, no less than 3 groups per batch).

[0022] Key operating points: Receive the continuously fed, opened fiber raw materials, accurately mix them according to the preset formula ratio (error ≤ ±1wt%), start the stirring program, and stop the machine every 5 minutes to check the mixing uniformity to ensure that the distribution of various fibers is not agglomerated; after mixing, the fibers are automatically sent to the carding and web laying process through the conveying device, without the need for manual transfer, thus avoiding deviations in the formula ratio.

[0023] Process objective: To achieve uniform mixing of different fibers, ensure consistent composition of subsequent board substrates, avoid local performance differences (such as insufficient local heat resistance or strength), ensure stable operation of continuous production lines, and provide a uniform raw material base for subsequent processes.

[0024] Step c, sorting and laying the web (third process in a continuous production line): Operating equipment: carding machine + cross-laying machine (equipped with curtain conveyor, adjustable web thickness, and web flatness detection device), integrated into a continuous production line and connecting mixed processes.

[0025] Carding parameters: Carding machine needle cloth speed 200-300r / min, needle pitch 5-8mm, straightness of fiber monofilament after carding ≥90%; web laying speed 1-2m / min, web laying thickness adjusted according to the thickness requirements of the finished product (if the subsequent high temperature baking process is performed, 1.5-2 times the shrinkage amount needs to be reserved), matching the conveying speed of the subsequent process, and the web surface density is uniform (deviation ≤±5g / ㎡).

[0026] Key operating points: The loose fibers continuously fed from the mixing process are then fed into a carding machine where they are carded with needle cloth to align the fibers in the same direction and remove any remaining small fiber clumps. The carded fibers then enter a cross-laying machine, where a "longitudinal + transverse" cross-laying method is used to form a continuous fiber web blank (fiber web blank). The web blank is free of holes, missing materials, and accumulation. The formed fiber web blank is then directly conveyed to the next process, with the flatness of the web blank being checked simultaneously. Unqualified web blanks are removed in real time.

[0027] Process objective: To straighten the fiber arrangement direction, improve the overall strength and dimensional stability of the fiber web blank through cross-laying, ensure that the board structure is uniform after subsequent processing, and eliminate the risk of delamination and cracking, adapt to continuous production rhythm, and reduce the defect rate of subsequent processes.

[0028] Step d, needle punching (can be skipped, 4th step in a continuous production line, optional): Applicable scenarios: This step can only be used when it is necessary to improve the preforming strength of the fiber web blank (to facilitate subsequent process transportation and avoid web blank deformation). If the fiber web blank itself has moderate looseness and there is no pressure during transportation, this step can be skipped directly. When activated, it is integrated into the continuous production line and connects with the carding and web laying process.

[0029] Operating equipment: Needle punching machine (single needle plate / double needle plate, adjustable needle density, equipped with needle hole detection device), which can be seamlessly connected to continuous production line.

[0030] Needle punching parameters: needle punching density 100-150 needles / ㎡, needle punching depth 5-8mm, needle speed 800-1000 needles / min, shrinkage rate of blank thickness after needle punching ≤10%, synchronized with the production line conveying speed, and no obvious needle hole defects in the blank after needle punching (needle hole diameter ≤0.3mm).

[0031] Key operating points: The fiber web blank is continuously fed into the needle punching machine from the carding and web laying process. Through the piercing action of the needles, the fibers intertwine and entangle to form a preform (fiber web blank) with a certain strength. After needle punching, the surface of the blank is flat and there is no looseness or shedding of fibers when held by hand. The processed blank continues to enter the next process through the conveying device to achieve continuous flow. Blanks that fail the needle hole detection are rejected in real time.

[0032] Process objective: To improve the preforming strength of fiber mesh blanks, facilitate the conveying and positioning of subsequent processes, reduce blank deformation and displacement, ensure the smooth operation of continuous production lines, and at the same time avoid excessively large pinholes that may affect the subsequent performance of the boards.

[0033] Step e, High-temperature baking (5th step in continuous production line, core auxiliary step, optional, can be skipped): Applicable scenarios: This process is only activated when it is necessary to improve the bonding strength of the fiber web blank (fiber web blank) in advance and optimize the effect of subsequent secondary heating and molding. If the bonding potential of the fiber web blank itself meets the requirements of secondary heating and cold pressing, this process can be skipped directly. When activated, it is integrated into the continuous production line and connected to the needle punching process (or the carding and web laying process; if needle punching is skipped), and the subsequent cooling and molding process (process 6) must be executed simultaneously.

[0034] Operating equipment: Continuous high-temperature baking oven (equipped with temperature control system, uniform speed conveyor, oven temperature uniformity ≤ ±5℃, equipped with real-time temperature monitoring and alarm device), which is an auxiliary heating equipment for continuous production lines.

[0035] Baking parameters: Baking temperature 130-180℃ (adjusted according to fiber formula; 150-180℃ when polyester fiber content is high, 140-175℃ when auxiliary fibers are included), baking time 12-18min (adjusted according to the thickness of the wire mesh; for every 10mm increase in thickness, extend the baking time by 3-4min), conveying speed 0.8-1.5m / min, maintain a slight positive pressure inside the oven (pressure 0.01-0.02MPa) to prevent cold air from entering and affecting the baking effect, and match the conveying speed of the preceding and following processes.

[0036] Key operating points: The fiber web blank (or needle-punched preform blank, i.e., fiber web blank) is laid flat on the conveyor belt of the baking oven through a continuous conveying device, ensuring that the blank is centered, without deviation, and without stacking; the baking oven is started and the temperature is increased according to the preset parameters to ensure that the temperature in all areas of the oven is uniform, avoiding excessive local temperature that may cause fiber carbonization or over-scorching, or insufficient temperature that may cause insufficient fiber melting and insufficient bonding force; the oven temperature and conveying speed are monitored in real time during the baking process, and an alarm is automatically triggered and adjustments are made when the temperature deviation exceeds ±5℃; after baking, the blank is directly sent to the cooling and forming process (step 6) through the conveying device, without manual contact, to avoid deformation of the blank.

[0037] Process objective: By baking at high temperature and uniformly, the initial bonding strength of the fiber mesh blank is improved, laying the foundation for subsequent cooling and forming and secondary heating and cold pressing of the thin-edged layer, optimizing the core physical properties of the board, and making it suitable for scenarios with high strength requirements; this process is an auxiliary process and can be selected for execution according to product requirements without affecting the integrity of the core process.

[0038] Step f, Cooling and forming (6th step in a continuous production line, auxiliary step, optional, can be skipped): Applicable scenarios: It is only activated after the high-temperature baking process (step 5). If the high-temperature baking process is skipped, this process will also be skipped. It is integrated into the end of a continuous production line to connect with the high-temperature baking process.

[0039] Operating equipment: Cooling conveyor (equipped with a cold water circulation system, flattening device, adjustable cooling temperature, and flatness detection device), integrated at the end of the continuous production line.

[0040] Cooling parameters: Cooling temperature 25-35℃ (room temperature cooling to avoid sudden cooling causing sheet cracking and warping), cooling time 20-30min, conveying speed synchronized with the baking oven discharge speed (0.8-1.5m / min), flattening device pressure 0.5-1.0MPa to ensure continuous flow, and the flatness deviation of the cooled sheet (fiber mesh blank solidified blank) ≤0.3mm / m.

[0041] Key operating points: After high-temperature baking, the fiber preform (fiber web preform) is taken out of the baking oven through a continuous conveyor and immediately sent to a cooling conveyor. It is cooled by circulating cold water, and at the same time, the flattening device is activated to ensure that the preform is flat and free of warping. During the cooling process, avoid stacking and squeezing the preforms to prevent deformation. After cooling and forming, the preform is free of warping, cracking, bulging, and bubbles, forming a regular hard preform. It is then sent out of the continuous production line through the conveyor to enter the subsequent heating and cold pressing process (step 7). Preforms that fail the flatness test are rejected in real time.

[0042] Process objective: To fix the forming structure of the blank after high-temperature baking, reduce the internal stress of the blank, improve dimensional stability, ensure the smooth progress of the subsequent secondary heating and cold pressing staggered thin-edge process, and avoid deformation and cracking during processing; it is only an auxiliary process to the 5th process and is not performed independently.

[0043] Step g, Heating and Cold Pressing Process (Step 7, Separate Process, Core Protection Point, Cannot Be Replaced): Operational logic: This process is a core and irreplaceable process. It must be performed regardless of whether processes 5 or 6 are performed. The fiber web blank (or fiber-cured blank) processed by process 4 (or process 6, when process 5 is performed) is first heated as a whole through a heating tunnel, and then sent to a cold press to complete the staggered thin-edge forming, realizing the integrated processing of "heating-cold pressing".

[0044] Operating equipment: The equipment is an integrated processing system, including a heating oven (equipped with a temperature control system, a uniform speed conveyor, a furnace temperature uniformity of ≤±5℃, an adjustable temperature range of 100-200℃, and a real-time temperature monitoring and alarm device) and a special cold press (equipped with a staggered forming mold, a four-sided positioning device, and a pressure control system, which can accurately match the forming requirements of the heated fiber web blank, and is equipped with a thin edge size detection device), which is the core process equipment and connects to the 4th (or 6th) process.

[0045] Process parameters: 1. Heating tunnel parameters: Heating temperature 100-200℃ (adjusted according to fiber formula and pre-processing conditions; 150-200℃ when polyester fiber content is high, 130-180℃ when auxiliary fibers are included), heating time 3-6min, conveying speed 0.5-1.0m / min, maintaining a slight positive pressure in the tunnel (pressure 0.01-0.02MPa) to ensure uniform heating of the fiber web blank, without local overheating or underheating; 2. Cold pressing parameters: Cold pressing temperature 25-35℃, cold pressing pressure 2-3MPa, cold pressing time 5-8min; staggered thin edge forming dimensions: width 5-45mm (covering different installation scenario requirements, plugging the loophole of "size fine adjustment avoidance"), thickness is 1 / 3 to 1 / 2 of the thickness of the finished board body, the thin edge transitions smoothly with the body, the staggered structure is regular, without steps, burrs, or chipped edges, and the thin edge is dense without gaps.

[0046] Key Operating Points: The fiber mesh blank processed in step 4 (if steps 5 and 6 are not performed) or the fiber-cured blank processed in step 6 (if steps 5 and 6 are performed) is transferred to the heating and drying tunnel conveyor. It is laid flat and precisely positioned (positioning deviation ≤ ±0.1mm). The heating tunnel is started, and the fiber mesh blank (or cured blank) is uniformly heated according to preset parameters, causing the fibers (or edge fibers of the blank) to soften slightly (without carbonization or flow). After heating, the fiber mesh blank (or cured blank) is seamlessly fed into a dedicated cold press via the conveyor. It is then precisely fixed again by a four-sided positioning device. The cold pressing program is started, and pressure is applied through a staggered forming mold to press the softened parts of the four sides of the fiber mesh blank (or cured blank) into preset staggered thin edges. Pressure is kept stable during cold pressing to avoid dimensional deviations. After cold pressing, the pressure is slowly released, and the formed sheet is removed. The staggered thin edge forming effect is checked by a testing device. If qualified, it proceeds to the next separate surface treatment process; unqualified products are reworked.

[0047] Process objective: The fiber mesh blank (or cured blank) is uniformly heated throughout by a heating tunnel, and then the staggered thin edges are precisely formed by a cold press. This provides the core structural foundation for subsequent staggered stacking and pressure-sensitive adhesive bonding between boards, ensuring seamless and firm splicing while guaranteeing edge strength and preventing damage during splicing. This process is the core of staggered structure forming and cannot be replaced by other forming methods (such as mechanical trimming or one-time hot pressing). It is also unaffected by whether or not the 5th and 6th processes are performed, and the core processing logic is irreplaceable.

[0048] Step h, Surface treatment (8th process, separate process, core optimization: expanding the range of treatment methods and strengthening environmental protection requirements): Operating equipment: basic equipment (surface dust removal device), supporting equipment (roller coating machine, spraying machine, printing machine, heat transfer machine, wear-resistant layer laminating machine, decorative layer laminating machine), which can be matched as needed according to the processing method. It is a core piece of equipment for a separate process, connecting the secondary heating and cold pressing process; all equipment is adapted to formaldehyde-free and PVC-free environmental protection process requirements, and the use of treatment materials containing VOCs and halogens is prohibited.

[0049] Basic processing parameters: Dust removal pressure 0.3-0.5MPa, using a combination of high-pressure airflow and electrostatic dust removal to ensure that the surface is free of dust and fine fiber residue, laying a clean foundation for subsequent surface treatment.

[0050] Specific processing methods (any one or more of the following methods can be combined): (1) Coating treatment (roller coating / spray coating): Select formaldehyde-free and VOC-free environmentally friendly coatings (including water-based coatings and powder coatings), roller coating speed 30-50r / min, coating thickness 5-12μm; spraying pressure 0.2-0.4MPa, coating thickness 3-8μm; post-coating curing temperature 60-80℃, curing time 8-10min, to ensure uniform coating, no missed coating, no sagging, no bubbles, and adhesion ≥1 level.

[0051] (2) Printing process (printing / heat transfer): The printing uses environmentally friendly water-based ink with a resolution of ≥300dpi. After printing, it is cured at low temperature (50-60℃, 6-8min), and the pattern is clear, without smudging or fading. The heat transfer temperature is 120-140℃, the transfer time is 2-3min, and the pressure is 0.1-0.2MPa. The transferred pattern adheres tightly to the surface of the board without lifting or scratches, and is suitable for different decorative styles.

[0052] (3) Add a wear-resistant layer: Select an environmentally friendly wear-resistant film (such as PET wear-resistant film or PP wear-resistant film), with a thickness of 0.1-0.3mm, and bond it by hot pressing. The hot pressing temperature is 100-120℃, the pressure is 1.5-2.0MPa, and the bonding time is 3-5min. After the wear-resistant layer is bonded, there are no bubbles or delamination, and the wear resistance is ≥4000 revolutions, which is suitable for high-frequency use scenarios such as flooring.

[0053] (4) Surface composite with various decorative layers: It can be composited with environmentally friendly decorative layers such as decorative film, fabric, thin wood, artificial stone, and metal foil. The composite method is hot pressing or environmentally friendly pressure-sensitive adhesive bonding (formaldehyde-free); hot pressing composite parameters: temperature 110-130℃, pressure 1.2-1.8MPa, time 4-6min; pressure-sensitive adhesive bonding parameters: adhesive amount 8-12g / ㎡, pressure 0.5-1.0MPa after bonding, and stand for 10-15min; after composite, the decorative layer is firmly bonded to the main body of the board, without loosening or lifting edges, and the surface of the decorative layer is free from damage and color difference.

[0054] Key points of operation: First, perform basic grinding and dust removal on the sheet material that has been heated and cold-pressed to form a staggered thin edge, ensuring that the surface is clean and flat; then, according to the product usage scenario and decoration requirements, select one or more of the above surface treatment methods and complete the treatment according to the corresponding parameters; after the treatment is completed, check the surface effect to ensure that there are no scratches, no color difference, no coating peeling / decorative layer delamination, and proceed to the next separate cutting process after passing the test.

[0055] Process Objectives: To optimize the product's appearance and texture, enrich the decorative effect, enhance the surface's wear resistance, antibacterial properties, stain resistance, and other additional properties, improve the product's weather resistance and service life, adapt to the usage needs of different scenarios such as flooring, wall panels, and ceilings, and lay the foundation for subsequent cutting and finished product inspection; explicitly prohibit the use of PVC decorative layers, and strengthen environmental protection restrictions.

[0056] Step i, Cutting (9th process, separate process): Operating equipment: CNC panel cutting machine (equipped with a precision positioning device, cutting accuracy ≤ ±0.2mm, and a size detection device).

[0057] Key operating points: Transfer the surface-treated sheets to the CNC cutting machine. According to the customer's order requirements (standard or customized sizes, such as squares, rectangles, hexagons, etc.), set the cutting size and cutting path, and start the cutting program. During the cutting process, ensure that the sheets are firmly fixed to avoid cutting deviation. After cutting, the edges of the sheets should be flat, without burrs or chipping, and the thin edges of the misaligned sheets should be undamaged. The surface coating / decorative layer should be free of scratches, and the dimensional deviation should meet the order requirements (deviation ≤ ±0.2mm). After cutting, check the dimensional accuracy with an inspection device, and rework any unqualified products.

[0058] Process objective: To cut the molded sheet into finished product sizes that meet market demands, adapting it to different installation scenarios, while also trimming the edges to improve the product's appearance and texture, laying the foundation for finished product inspection.

[0059] Finished Product Inspection: All cut finished products undergo full inspection, including: dimensional accuracy, thickness of thin edges, surface treatment effect (coating adhesion / decorative layer fit, surface roughness, abrasion resistance), appearance quality (no burrs, chipping, bulging, color difference, coating peeling / decorative layer delamination), environmental performance (no formaldehyde, no PVC, no VOC), acoustic performance (NRC, IIC), and fire resistance (up to national standard GB8624-2012: Class B, European standard EN 13501-1: Class B; American standard ASTM E-84, Class A). Only products that pass the inspection can be put into storage; unqualified products are prohibited from being put into storage. Samples of each batch of finished products are retained for a period of not less than 3 years to facilitate subsequent quality traceability and rights protection.

[0060] Packaging and Warehousing: Qualified finished products are packaged in moisture-proof packaging materials (such as pearl cotton + cardboard boxes), and the product specifications, thickness, batch, environmental certification, surface treatment method, production date and other information are marked. They are then stored in dry and ventilated warehouses according to batches to avoid moisture, deformation due to squeezing, and damage to the coating / decorative layer.

[0061] The beneficial effects of this invention are as follows: (1) This invention uses polyester fiber as the base material and heat-melt bonding to form an integrated fiber-based staggered composite decorative panel. The adjacent panels are connected by an integrated method of "staggered composite + environmentally friendly pressure-sensitive adhesive". There are no locks, no male and female grooves, no double-layer composite, no buckles, no plugs, and no tenons. After splicing, a seamless overall surface layer is formed, which can quickly complete the splicing and installation. The structure is simple and the assembly operation is convenient. The stepped thin edge and the suspended thin edge are dense without gaps. The thin edge and the main body are smoothly transitioned without steps, burrs, or chipped edges. (2) The present invention allows the surface of the board to be treated by one or more environmentally friendly methods such as coating, printing, wear-resistant layer, composite decorative layer, etc., to meet different decoration and use needs; the substrate is polyester fiber and polypropylene fiber (which may contain a small amount of environmentally friendly auxiliary fiber) hot-pressed, without PVC or formaldehyde, and is recyclable as a whole, with dimensional stability ≤0.1% (24h immersion test), ensuring structural stability and performance.

[0062] In summary, this invention has the advantages of being environmentally friendly, safe and reliable, easy to assemble, simple in structure, integrally molded, and high in strength, and is especially suitable for the field of polyester fiber sheet technology. Attached Figure Description

[0063] Figure 1 This is a schematic diagram of the three-dimensional structure of the fiber-based staggered laminated decorative panel of the present invention; Figure 2 for Figure 1 Enlarged schematic diagram of the structure at point A in the middle; Figure 3 This is a schematic diagram of the splicing structure of the fiber-based staggered laminated decorative panel of the present invention; Figure 4 This is a flowchart illustrating the manufacturing process of the fiber-based staggered laminated decorative panel of the present invention. Detailed Implementation

[0064] 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.

[0065] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," and "counterclockwise," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0066] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified.

[0067] Example 1: like Figures 1-3 As shown, a fiber-based staggered laminated decorative panel is composed of a square panel body 1 and stepped thin edges 2 and suspended thin edges 3 extending outward from the panel body 1. The stepped thin edges 2 and suspended thin edges 3 are arranged adjacent to each other. Furthermore, the main body 1, the stepped thin edge 2, and the suspended thin edge 3 of the board are all made of polyester fiber as the base material through hot melt bonding and pressing, and contain 100wt% polyester fiber by mass percentage.

[0068] It should be noted that the board body 1 is the basic load-bearing unit, which has a square structure and provides the core strength and the foundation for the decorative surface. The surface can be processed into a flat, frosted or custom texture according to the requirements. The board body, stepped thin edges, and suspended thin edges are formed by hot pressing in one piece, without splicing seams. The edge impact resistance is enhanced, which is 50% higher than that of traditional spliced ​​boards. There is no risk of fragments falling after impact.

[0069] When adjacent boards are spliced, the stepped thin edge of board A is embedded under the suspended thin edge of board B. The mating surfaces are connected by double-sided tape. During cold pressing, the roughness of the mating surfaces can be increased by setting concave and convex textures to improve the adhesion strength between the double-sided tape and the mating surfaces. Board A and board B form a staggered interlocking structure of "top pressing down and edge interlocking". The elastic deformation of the thin edges achieves a tight fit without the need for additional connectors. The layering of the stepped thin edges and the elastic overlap of the suspended thin edges increase the contact area of ​​the splicing surface by more than 30%, and the pull-out resistance is far greater than that of traditional splicing structures. Even on uneven base surfaces, it can prevent loosening. With optimized sealing performance, a natural sealed cavity is formed after splicing, solving the hidden dangers of dirt and water ingress in traditional splicing, and is especially suitable for humid environments such as kitchens and bathrooms; The installation flexibility is improved, no installation space needs to be reserved, and "dry quick installation" can be achieved. The construction efficiency is 40% higher than that of traditional mortise and tenon structure. A single person can complete the splicing. During maintenance, individual panels can be disassembled without affecting the overall structure.

[0070] Example 2: Referring to Example 1, the difference between Example 2 and Example 1 lies in the following: like Figure 1 As shown, a fiber-based staggered laminated decorative panel contains 40-70 wt% polyester fiber and 60-30 wt% polypropylene fiber by mass percentage.

[0071] It should be noted that polyester fiber (PET, 40-70wt%) provides structural rigidity and basic sound-absorbing skeleton, while polypropylene fiber (PP, 60-30wt%) serves as a hydrophobic modification and low-temperature bonding component, which significantly improves waterproof / moisture-proof performance. At the same time, the amount of polypropylene added will significantly change the key properties of the board, such as its thermal processability, mechanical toughness, acoustic porosity, density, and weather resistance.

[0072] Polypropylene (PP) is a completely non-polar hydrophobic fiber (surface contact angle > 90°, non-absorbent and non-conductive). Compared to polyester fiber (PET, which has slight moisture absorption), the waterproof performance is significantly improved after blending. The water absorption rate is significantly reduced. The water absorption rate of pure polyester sound-absorbing board is about 3-5%. After adding 60-30wt% polypropylene, the saturated water absorption rate of the board can be reduced to below 0.5%, and it absorbs almost no water. The dimensional stability of the board is ≤0.1% (24h immersion test). Enhanced water repellency and seepage prevention: Polypropylene forms a continuous hydrophobic network, causing moisture to remain only on the surface of the board (as water droplets rolling off), without penetrating or spreading, thus solving the problems of pure polyester boards becoming damp, seeping water, and moldy. Improved dimensional stability in wet conditions, no moisture absorption expansion / softening, no arching, deformation or delamination in humid environments (high humidity workshops, basements, bathrooms, outdoor eaves); With optimized anti-mildew and anti-corrosion properties, the hydrophobic structure blocks the nutrient source of mold, ensuring that the board does not develop mold, odor, or fiber powdering even under long-term high humidity conditions.

[0073] In addition, the melting point of polypropylene (110-130℃) is much lower than that of polyester (255℃). The higher the amount of polypropylene added, the lower the hot pressing temperature of the sheet (which can be reduced by 30-50℃), resulting in lower energy consumption and improved production efficiency. Polypropylene melts first to act as an in-situ binder to bond the fibers.

[0074] Furthermore, polypropylene enhances impact resistance and toughness, addressing the "brittle and easily cracked" defects of pure polyester boards. With 30-50wt% polypropylene fiber, the balance between rigidity and toughness is optimal, making it impact-resistant, bend-resistant, and less prone to breakage, suitable for irregular / curved processing. With 50-60wt% polypropylene fiber, flexibility and elasticity are improved, making it more resistant to impacts, but rigidity / hardness is slightly reduced, resulting in a softer board and reduced load-bearing capacity.

[0075] Regarding the sound absorption performance of the board, with 30-50wt% polypropylene fiber, the board has uniform pores and good connectivity, and the mid-to-high frequency sound absorption coefficient remains at 0.8-1.0 (comparable to pure polyester board); with 50-60wt% polypropylene fiber, the molten bonding is too dense, the porosity decreases and the pore size becomes smaller, and the mid-to-high frequency sound absorption coefficient decreases slightly (by 5-15%).

[0076] Example 3: Referring to Example 1, the difference between Example 3 and Example 1 lies in the following: like Figure 1 As shown, a fiber-based staggered laminated decorative panel contains ≥70wt% polyester fiber and the remainder is polypropylene fiber by mass percentage.

[0077] Polypropylene accounts for only ≤30%, which cannot form a continuous hydrophobic network. The improvement in waterproofing is limited but practical. Compared with pure polyester board, the water absorption rate is reduced from 3-5% to 1-2%, and the surface hydrophobicity is improved. It has obvious effects in daily moisture prevention, condensation prevention, and prevention of slight dampness. It is not easy to mold or efflorescence. Compared with high polypropylene formula, it does not have strong hydrophobic and water-repellent functions and is not suitable for high humidity, water spray, and semi-outdoor environments. It is only suitable for indoor dry / slightly humid scenarios (such as conference rooms, classrooms, and home decoration). Its rigidity / bending resistance is far superior to high polypropylene technology solutions. The board does not soften, sag, or deform. It is suitable for large-area walls and ceilings, with better load-bearing capacity. At the same time, its toughness is 10-20% higher than that of pure polyester board. Polypropylene fibers play a slight toughening role, reducing brittleness and edge chipping. It has lower transportation and installation losses. It is suitable for mainstream indoor scenarios with priority given to acoustics and normal humidity, such as conference rooms, classrooms, audio-visual rooms, offices, home decoration living rooms / studies, theaters, and libraries.

[0078] Example 4: Referring to Example 1, the difference between Example 4 and Example 1 lies in the following: like Figure 1 As shown, a fiber-based staggered laminated decorative panel contains, by weight percentage, 35-75 wt% polyester fiber, 25-65 wt% polypropylene fiber, and 0-10 wt% environmentally friendly auxiliary fiber, which is one of bamboo fiber and hemp fiber.

[0079] Bamboo fiber and hemp fiber are natural long and tough fibers. When added, they are like adding "natural ribs" to the board, which greatly improves the bending strength, impact resistance and flexural strength, making the board less prone to breakage, cracking and deformation. They are especially suitable for high toughness requirements such as irregularly shaped boards, curved decorations and column cladding.

[0080] After degreasing and drying, natural plant fibers have better dimensional stability than ordinary recycled fibers. Combined with a staggered layered structure, they can further reduce the expansion, contraction, and warping of boards caused by changes in temperature and humidity, resulting in a smoother finish when installed on walls or ceilings.

[0081] Furthermore, by adding flame-retardant modified bamboo / hemp fiber, the fire resistance rating of the board can be improved without using flame-retardant adhesive or increasing VOCs, thus meeting the fire protection acceptance standards for public buildings and directly expanding the engineering application market.

[0082] Example 5: like Figure 4 As shown, the preparation method of a fiber-based staggered laminated decorative panel of Example 5 of the present invention is described with reference to Examples 1-4, including the following steps: Step a, Fiber opening (first process in a continuous production line): Operating equipment: Twin-shaft opening machine (equipped with carding rollers and beater rollers, with adjustable speed), integrated at the front end of the continuous production line, seamlessly connected with subsequent mixing processes, and adaptable to the processing of fiber raw materials of different lengths and fineness.

[0083] Raw material requirements: Use dry, impurity-free polyester fibers (length 38-65mm, fineness 1.5-25D) and polypropylene fibers (length 38-65mm, fineness 2.0-25D). Auxiliary fibers (if selected) should be 35-60mm in length and 2.0-20D in fineness. The melting point of polyester fibers should be 255-260℃, and the melting point of polypropylene fibers should be 165-175℃. The moisture content of the raw materials should be ≤8%, and there should be no lumps or oil stains.

[0084] Key operating points: Feed the fiber raw materials of the formula ratio into the opening machine in batches, adjust the speed of the beater roller to 800-1200 r / min and the speed of the carding roller to 300-500 r / min. Through mechanical beating and combing, break up the fiber bundles and make the fibers into loose monofilaments. Remove dust and impurities from the raw materials (impurity screening accuracy ≥98%) to ensure that the fibers are evenly dispersed and free from obvious clumps and lint. The processed loose fibers are directly sent to the next mixing process through the conveyor device to achieve continuous production without manual secondary transfer and avoid secondary fiber agglomeration.

[0085] Process objective: To loosen fiber bundles, laying the foundation for subsequent mixing and web laying, avoiding fiber agglomeration that leads to uneven density and insufficient strength within the board, adapting to the high-efficiency operation requirements of continuous production lines, while ensuring the cleanliness of raw materials and guaranteeing the environmental performance of the product.

[0086] Step b, mixing (second process in a continuous production line): Operating equipment: High-speed mixer (with stirring paddle, adjustable stirring speed and time, and equipped with temperature monitoring device), connected after the fiber opening process, is one of the core equipment of the continuous production line.

[0087] Mixing parameters: stirring speed 500-800 r / min, mixing time 15-25 min, mixing temperature controlled at 0-40℃ (room temperature mixing to avoid premature softening of fibers), mixing uniformity ≥95% (sampling test, no less than 3 groups per batch).

[0088] Key operating points: Receive the continuously fed, opened fiber raw materials, accurately mix them according to the preset formula ratio (error ≤ ±1wt%), start the stirring program, and stop the machine every 5 minutes to check the mixing uniformity to ensure that the distribution of various fibers is not agglomerated; after mixing, the fibers are automatically sent to the carding and web laying process through the conveying device, without the need for manual transfer, thus avoiding deviations in the formula ratio.

[0089] Process objective: To achieve uniform mixing of different fibers, ensure consistent composition of subsequent board substrates, avoid local performance differences (such as insufficient local heat resistance or strength), ensure stable operation of continuous production lines, and provide a uniform raw material base for subsequent processes.

[0090] Step c, sorting and laying the web (third process in a continuous production line): Operating equipment: carding machine + cross-laying machine (equipped with curtain conveyor, adjustable web thickness, and web flatness detection device), integrated into a continuous production line and connecting mixed processes.

[0091] Carding parameters: Carding machine needle cloth speed 200-300r / min, needle pitch 5-8mm, straightness of fiber monofilament after carding ≥90%; web laying speed 1-2m / min, web laying thickness adjusted according to the thickness requirements of the finished product (if the subsequent high temperature baking process is performed, 1.5-2 times the shrinkage amount needs to be reserved), matching the conveying speed of the subsequent process, and the web surface density is uniform (deviation ≤±5g / ㎡).

[0092] Key operating points: The loose fibers continuously fed from the mixing process are then fed into a carding machine where they are carded with needle cloth to align the fibers in the same direction and remove any remaining small fiber clumps. The carded fibers then enter a cross-laying machine, where a "longitudinal + transverse" cross-laying method is used to form a continuous fiber web blank (fiber web blank). The web blank is free of holes, missing materials, and accumulation. The formed fiber web blank is then directly conveyed to the next process, with the flatness of the web blank being checked simultaneously. Unqualified web blanks are removed in real time.

[0093] Process objective: To straighten the fiber arrangement direction, improve the overall strength and dimensional stability of the fiber web blank through cross-laying, ensure that the board structure is uniform after subsequent processing, and eliminate the risk of delamination and cracking, adapt to continuous production rhythm, and reduce the defect rate of subsequent processes.

[0094] Step d, needle punching (can be skipped, 4th step in a continuous production line, optional): Applicable scenarios: This step can only be used when it is necessary to improve the preforming strength of the fiber web blank (to facilitate subsequent process transportation and avoid web blank deformation). If the fiber web blank itself has moderate looseness and there is no pressure during transportation, this step can be skipped directly. When activated, it is integrated into the continuous production line and connects with the carding and web laying process.

[0095] Operating equipment: Needle punching machine (single needle plate / double needle plate, adjustable needle density, equipped with needle hole detection device), which can be seamlessly connected to continuous production line.

[0096] Needle punching parameters: needle punching density 100-150 needles / ㎡, needle punching depth 5-8mm, needle speed 800-1000 needles / min, shrinkage rate of blank thickness after needle punching ≤10%, synchronized with the production line conveying speed, and no obvious needle hole defects in the blank after needle punching (needle hole diameter ≤0.3mm).

[0097] Key operating points: The fiber web blank is continuously fed into the needle punching machine from the carding and web laying process. Through the piercing action of the needles, the fibers intertwine and entangle to form a preform (fiber web blank) with a certain strength. After needle punching, the surface of the blank is flat and there is no looseness or shedding of fibers when held by hand. The processed blank continues to enter the next process through the conveying device to achieve continuous flow. Blanks that fail the needle hole detection are rejected in real time.

[0098] Process objective: To improve the preforming strength of fiber mesh blanks, facilitate the conveying and positioning of subsequent processes, reduce blank deformation and displacement, ensure the smooth operation of continuous production lines, and at the same time avoid excessively large pinholes that may affect the subsequent performance of the boards.

[0099] Step e, High-temperature baking (5th step in continuous production line, core auxiliary step, optional, can be skipped): Applicable scenarios: This process is only activated when it is necessary to improve the bonding strength of the fiber web blank (fiber web blank) in advance and optimize the effect of subsequent secondary heating and molding. If the bonding potential of the fiber web blank itself meets the requirements of secondary heating and cold pressing, this process can be skipped directly. When activated, it is integrated into the continuous production line and connected to the needle punching process (or the carding and web laying process; if needle punching is skipped), and the subsequent cooling and molding process (process 6) must be executed simultaneously.

[0100] Operating equipment: Continuous high-temperature baking oven (equipped with temperature control system, uniform speed conveyor, oven temperature uniformity ≤ ±5℃, equipped with real-time temperature monitoring and alarm device), which is an auxiliary heating equipment for continuous production lines.

[0101] Baking parameters: Baking temperature 130-180℃ (adjusted according to fiber formula; 150-180℃ when polyester fiber content is high, 140-175℃ when auxiliary fibers are included), baking time 12-18min (adjusted according to the thickness of the wire mesh; for every 10mm increase in thickness, extend the baking time by 3-4min), conveying speed 0.8-1.5m / min, maintain a slight positive pressure inside the oven (pressure 0.01-0.02MPa) to prevent cold air from entering and affecting the baking effect, and match the conveying speed of the preceding and following processes.

[0102] Key operating points: The fiber web blank (or needle-punched preform blank, i.e., fiber web blank) is laid flat on the conveyor belt of the baking oven through a continuous conveying device, ensuring that the blank is centered, without deviation, and without stacking; the baking oven is started and the temperature is increased according to the preset parameters to ensure that the temperature in all areas of the oven is uniform, avoiding excessive local temperature that may cause fiber carbonization or over-scorching, or insufficient temperature that may cause insufficient fiber melting and insufficient bonding force; the oven temperature and conveying speed are monitored in real time during the baking process, and an alarm is automatically triggered and adjustments are made when the temperature deviation exceeds ±5℃; after baking, the blank is directly sent to the cooling and forming process (step 6) through the conveying device, without manual contact, to avoid deformation of the blank.

[0103] Process objective: By baking at high temperature and uniformly, the fibers are partially melted, which improves the initial bonding strength of the fiber web blank, lays the foundation for subsequent cooling and forming and secondary heating and cold pressing of the thin-edged layers, optimizes the core physical properties of the board, and is suitable for scenarios with high strength requirements. This process is an auxiliary process and can be selected for execution according to product requirements without affecting the integrity of the core process.

[0104] Step f, Cooling and forming (6th step in a continuous production line, auxiliary step, optional, can be skipped): Applicable scenarios: It is only activated after the high-temperature baking process (step 5). If the high-temperature baking process is skipped, this process will also be skipped. It is integrated into the end of a continuous production line to connect with the high-temperature baking process.

[0105] Operating equipment: Cooling conveyor (equipped with a cold water circulation system, flattening device, adjustable cooling temperature, and flatness detection device), integrated at the end of the continuous production line.

[0106] Cooling parameters: Cooling temperature 25-35℃ (room temperature cooling to avoid sudden cooling causing sheet cracking and warping), cooling time 20-30min, conveying speed synchronized with the baking oven discharge speed (0.8-1.5m / min), flattening device pressure 0.5-1.0MPa to ensure continuous flow, and the flatness deviation of the cooled sheet (fiber mesh blank solidified blank) ≤0.3mm / m.

[0107] Key operating points: After high-temperature baking, the fiber preform (fiber web preform) is taken out of the baking oven through a continuous conveyor and immediately sent to a cooling conveyor. It is cooled by circulating cold water, and at the same time, the flattening device is activated to ensure that the preform is flat and free of warping. During the cooling process, avoid stacking and squeezing the preforms to prevent deformation. After cooling and forming, the preform is free of warping, cracking, bulging, and bubbles, forming a regular hard preform. It is then sent out of the continuous production line through the conveyor to enter the subsequent heating and cold pressing process (step 7). Preforms that fail the flatness test are rejected in real time.

[0108] Process objective: To fix the forming structure of the blank after high-temperature baking, reduce the internal stress of the blank, improve dimensional stability, ensure the smooth progress of the subsequent secondary heating and cold pressing staggered thin-edge process, and avoid deformation and cracking during processing; it is only an auxiliary process to the 5th process and is not performed independently.

[0109] Step g, Heating and Cold Pressing Process (Step 7, Separate Process, Core Protection Point, Cannot Be Replaced): Operational logic: This process is a core and irreplaceable process. It must be performed regardless of whether processes 5 or 6 are performed. The fiber web blank (or fiber-cured blank) processed by process 4 (or process 6, when process 5 is performed) is first heated as a whole through a heating tunnel, and then sent to a cold press to complete the staggered thin-edge forming, realizing the integrated processing of "heating-cold pressing".

[0110] Operating equipment: The equipment is an integrated processing system, including a heating oven (equipped with a temperature control system, a uniform speed conveyor, a furnace temperature uniformity of ≤±5℃, an adjustable temperature range of 100-200℃, and a real-time temperature monitoring and alarm device) and a special cold press (equipped with a staggered forming mold, a four-sided positioning device, and a pressure control system, which can accurately match the forming requirements of the heated fiber web blank, and is equipped with a thin edge size detection device), which is the core process equipment and connects to the 4th (or 6th) process.

[0111] Process parameters: 1. Heating tunnel parameters: Heating temperature 100-200℃ (adjusted according to fiber formula and pre-processing conditions; 150-200℃ when polyester fiber content is high, 130-180℃ when auxiliary fibers are included), heating time 3-6min, conveying speed 0.5-1.0m / min, maintaining a slight positive pressure in the tunnel (pressure 0.01-0.02MPa) to ensure uniform heating of the fiber web blank, without local overheating or underheating; 2. Cold pressing parameters: Cold pressing temperature 25-35℃, cold pressing pressure 2-3MPa, cold pressing time 5-8min; staggered thin edge forming dimensions: width 5-45mm (covering different installation scenario requirements, plugging the loophole of "size fine adjustment avoidance"), thickness is 1 / 3 to 1 / 2 of the thickness of the finished board body, the thin edge transitions smoothly with the body, the staggered structure is regular, without steps, burrs, or chipped edges, and the thin edge is dense without gaps.

[0112] Key Operating Points: The fiber mesh blank processed in step 4 (if steps 5 and 6 are not performed) or the fiber-cured blank processed in step 6 (if steps 5 and 6 are performed) is transferred to the heating and drying tunnel conveyor. It is laid flat and precisely positioned (positioning deviation ≤ ±0.1mm). The heating tunnel is started, and the fiber mesh blank (or cured blank) is uniformly heated according to preset parameters, causing the fibers (or edge fibers of the blank) to soften slightly (without carbonization or flow). After heating, the fiber mesh blank (or cured blank) is seamlessly fed into a dedicated cold press via the conveyor. It is then precisely fixed again by a four-sided positioning device. The cold pressing program is started, and pressure is applied through a staggered forming mold to press the softened parts of the four sides of the fiber mesh blank (or cured blank) into preset staggered thin edges. Pressure is kept stable during cold pressing to avoid dimensional deviations. After cold pressing, the pressure is slowly released, and the formed sheet is removed. The staggered thin edge forming effect is checked by a testing device. If qualified, it proceeds to the next separate surface treatment process; unqualified products are reworked.

[0113] Process objective: The fiber mesh blank (or cured blank) is uniformly heated throughout by a heating tunnel, and then the staggered thin edges are precisely formed by a cold press. This provides the core structural foundation for subsequent staggered stacking and pressure-sensitive adhesive bonding between boards, ensuring seamless and firm splicing while guaranteeing edge strength and preventing damage during splicing. This process is the core of staggered structure forming and cannot be replaced by other forming methods (such as mechanical trimming or one-time hot pressing). It is also unaffected by whether or not the 5th and 6th processes are performed, and the core processing logic is irreplaceable.

[0114] Step h, Surface treatment (8th process, separate process, core optimization: expanding the range of treatment methods and strengthening environmental protection requirements): Operating equipment: basic equipment (surface dust removal device), supporting equipment (roller coating machine, spraying machine, printing machine, heat transfer machine, wear-resistant layer laminating machine, decorative layer laminating machine), which can be matched as needed according to the processing method. It is a core piece of equipment for a separate process, connecting the secondary heating and cold pressing process; all equipment is adapted to formaldehyde-free and PVC-free environmental protection process requirements, and the use of treatment materials containing VOCs and halogens is prohibited.

[0115] Basic processing parameters: Dust removal pressure 0.3-0.5MPa, using a combination of high-pressure airflow and electrostatic dust removal to ensure that the surface is free of dust and fine fiber residue, laying a clean foundation for subsequent surface treatment.

[0116] Specific processing methods (any one or more of the following methods can be combined): (1) Coating treatment (roller coating / spray coating): Select formaldehyde-free and VOC-free environmentally friendly coatings (including water-based coatings and powder coatings), roller coating speed 30-50r / min, coating thickness 5-12μm; spraying pressure 0.2-0.4MPa, coating thickness 3-8μm; post-coating curing temperature 60-80℃, curing time 8-10min, to ensure uniform coating, no missed coating, no sagging, no bubbles, and adhesion ≥1 level.

[0117] (2) Printing process (printing / heat transfer): The printing uses environmentally friendly water-based ink with a resolution of ≥300dpi. After printing, it is cured at low temperature (50-60℃, 6-8min), and the pattern is clear, without smudging or fading. The heat transfer temperature is 120-140℃, the transfer time is 2-3min, and the pressure is 0.1-0.2MPa. The transferred pattern adheres tightly to the surface of the board without lifting or scratches, and is suitable for different decorative styles.

[0118] (3) Add a wear-resistant layer: Select an environmentally friendly wear-resistant film (such as PET wear-resistant film or PP wear-resistant film), with a thickness of 0.1-0.3mm, and bond it by hot pressing. The hot pressing temperature is 100-120℃, the pressure is 1.5-2.0MPa, and the bonding time is 3-5min. After the wear-resistant layer is bonded, there are no bubbles or delamination, and the wear resistance is ≥4000 revolutions, which is suitable for high-frequency use scenarios such as flooring.

[0119] (4) Surface composite with various decorative layers: It can be composited with environmentally friendly decorative layers such as decorative film, fabric, thin wood, artificial stone, and metal foil. The composite method is hot pressing or environmentally friendly pressure-sensitive adhesive bonding (formaldehyde-free); hot pressing composite parameters: temperature 110-130℃, pressure 1.2-1.8MPa, time 4-6min; pressure-sensitive adhesive bonding parameters: adhesive amount 8-12g / ㎡, pressure after bonding 0.5-1.0MPa, stand for 10-15min; after composite, the decorative layer is firmly bonded to the main body of the board, without loosening or lifting edges, and the surface of the decorative layer is undamaged and color-different.

[0120] Key points of operation: First, perform basic grinding and dust removal on the sheet material that has been heated and cold-pressed to form a staggered thin edge, ensuring that the surface is clean and flat; then, according to the product usage scenario and decoration requirements, select one or more of the above surface treatment methods and complete the treatment according to the corresponding parameters; after the treatment is completed, check the surface effect to ensure that there are no scratches, no color difference, no coating peeling / decorative layer delamination, and proceed to the next separate cutting process after passing the test.

[0121] Process Objectives: To optimize the product's appearance and texture, enrich the decorative effect, enhance the surface's wear resistance, antibacterial properties, stain resistance, and other additional properties, improve the product's weather resistance and service life, adapt to the usage needs of different scenarios such as flooring, wall panels, and ceilings, and lay the foundation for subsequent cutting and finished product inspection; explicitly prohibit the use of PVC decorative layers, and strengthen environmental protection restrictions.

[0122] Step i, Cutting (9th process, separate process): Operating equipment: CNC panel cutting machine (equipped with a precision positioning device, cutting accuracy ≤ ±0.2mm, and a size detection device).

[0123] Key operating points: Transfer the surface-treated sheets to the CNC cutting machine. According to the customer's order requirements (standard or customized sizes, such as squares, rectangles, hexagons, etc.), set the cutting size and cutting path, and start the cutting program. During the cutting process, ensure that the sheets are firmly fixed to avoid cutting deviation. After cutting, the edges of the sheets should be flat, without burrs or chipping, and the thin edges of the misaligned sheets should be undamaged. The surface coating / decorative layer should be free of scratches, and the dimensional deviation should meet the order requirements (deviation ≤ ±0.2mm). After cutting, check the dimensional accuracy with an inspection device, and rework any unqualified products.

[0124] Process objective: To cut the molded sheet into finished product sizes that meet market demands, adapting it to different installation scenarios, while also trimming the edges to improve the product's appearance and texture, laying the foundation for finished product inspection.

[0125] Finished Product Inspection: All cut finished products undergo full inspection, including: dimensional accuracy, thickness of thin edges, surface treatment effect (coating adhesion / decorative layer fit, surface roughness, abrasion resistance), appearance quality (no burrs, chipping, bulging, color difference, coating peeling / decorative layer delamination), environmental performance (no formaldehyde, no PVC, no VOC), acoustic performance (NRC, IIC), and fire resistance (up to national standard GB8624-2012: Class B, European standard EN 13501-1: Class B; American standard ASTM E-84, Class A). Only products that pass the inspection can be put into storage; unqualified products are prohibited from being put into storage. Samples of each batch of finished products are retained for a period of not less than 3 years to facilitate subsequent quality traceability and rights protection.

[0126] Packaging and Warehousing: Qualified finished products are packaged in moisture-proof packaging materials (such as pearl cotton + cardboard boxes), and the product specifications, thickness, batch, environmental certification, surface treatment method, production date and other information are marked. They are then stored in dry and ventilated warehouses according to batches to avoid moisture, deformation due to squeezing, and damage to the coating / decorative layer.

[0127] The fiber-based staggered laminated decorative panels of Examples 1-4 were prepared using the preparation method of Example 5 to form Preparation Examples 1-8. The sound absorption performance, water absorption thickness expansion rate, and thermal stability of the prepared fiber-based staggered laminated decorative panels (thickness 8 mm) were tested, and the test results are shown in the table below: Table 1. Test results of fiber-based staggered laminated decorative panels prepared in Examples 1-8 As shown in the table above, the fiber-based staggered laminated decorative panels prepared in Examples 1-8 have superior sound absorption performance, water immersion deformation, and thermal stability compared to existing sound-absorbing decorative panels. The fiber-based staggered laminated decorative panel in Example 1, made with pure polyester fiber, has mechanical properties and strength suitable for ceiling panels and wall panels (dry indoor environments). The fiber-based staggered laminated decorative panels in Examples 2-4 have strong waterproofing and good thermal stability, suitable for flooring and wall panels (high humidity / moisture-proof floors). The fiber-based staggered laminated decorative panels in Examples 5-6 have a balanced combination of waterproofing, sound absorption, and mechanical properties, suitable for wall panels and flooring (general-purpose). The addition of environmentally friendly fibers to the fiber-based staggered laminated decorative panels in Examples 7-8 balances the decrease in thermal stability caused by the reduced polyester fiber content, effectively preventing thermal deformation and warping of the panels while reducing manufacturing costs. Since the cost of polyester fiber is much higher than that of polypropylene fiber, it is suitable for wall panels and flooring (general-purpose).

[0128] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A fiber-based staggered laminated decorative panel, characterized in that: It consists of a square board body and stepped thin edges and suspended thin edges extending outward from the board body, with the stepped thin edges and suspended thin edges arranged adjacent to each other. Furthermore, the main body of the board, the stepped thin edge, and the suspended thin edge are all formed by hot-melting and pressing with fiber filaments as the base material.

2. The fiber-based staggered laminated decorative panel according to claim 1, characterized in that: It contains 100 wt% polyester fiber by weight percentage.

3. The fiber-based staggered laminated decorative panel according to claim 1, characterized in that: It contains 40-70 wt% polyester fiber and 60-30 wt% polypropylene fiber by weight percentage.

4. The fiber-based staggered laminated decorative panel according to claim 1, characterized in that: It contains ≥70wt% polyester fiber and the remainder is polypropylene fiber.

5. The fiber-based staggered laminated decorative panel according to claim 1, characterized in that: It contains 35-75 wt% polyester fiber, 25-65 wt% polypropylene fiber and 0-10 wt% environmentally friendly auxiliary fiber by weight percentage. The environmentally friendly auxiliary fiber is one of bamboo fiber and hemp fiber.

6. A process for manufacturing the fiber-based staggered laminated board according to any one of claims 1-5, characterized in that, Includes the following steps: Step a: Fiber opening. The fiber raw materials in the formula ratio are fed into the opening machine in batches. Through mechanical beating and combing, the fiber bundles are broken up and the fibers are made into loose monofilaments. Dust and impurities in the raw materials are removed to ensure that the fibers are evenly dispersed and free from obvious clumps and tufts. Step b: Fiber mixing. After opening, the fiber raw materials are precisely proportioned according to the preset formula and put into a high-speed mixer. Start stirring and stop the machine every 5 minutes to check the uniformity of mixing to ensure that there is no agglomeration of various fibers. Step c: Carding and web laying. The loose fibers continuously conveyed from the mixing process are received and fed into the carding machine to be carded by the carding cloth so that the fibers are arranged in the same direction and the residual small fiber clumps are removed. The carded fibers enter the cross-laying machine and are laid in a longitudinal and transverse cross-laying manner to form a continuous fiber web blank. The web blank has no holes, missing materials, or accumulation. Step d, needle punching: The fiber web blank is continuously fed into the needle punching machine from the carding and web laying process. Through the piercing action of the needles, the fibers intertwine and entangle with each other to form a preform with a certain strength. After needle punching, the surface of the blank is flat and there is no looseness or shedding of fibers when held by hand. Step e, high-temperature baking: The fiber web blank is laid flat on the conveyor belt of the baking oven through a continuous conveying device to ensure that the blank is centered, without deviation or stacking; the baking oven is started and the temperature is increased according to the preset parameters. Through high-temperature uniform baking, the fibers are partially melted, which improves the initial bonding strength of the fiber web blank. If step e is skipped, proceed directly to step g. Step f, cooling: After high-temperature baking, the fiber web blank is taken out of the baking oven through a continuous conveying device and immediately sent to a cooling conveyor. It is cooled by circulating cold water, and at the same time, the flattening device is started to ensure that the fiber web blank is flat and without warping. After cooling and molding, a regular solidified blank is formed. Step g, heating and cold pressing molding: The fiber mesh blank output in step d or the rigid blank output in step f is heated again in a heating tunnel to make the fiber mesh blank or solidified blank slightly soft. After heating, the fiber mesh blank or solidified blank is pressed into the preset stepped thin edge and suspended thin edge by a special cold press. Step h, Surface treatment: First, perform basic grinding and dust removal on the heated and cold-pressed board to ensure a clean and flat surface. Then, depending on the product's usage scenario and decoration requirements, select one or more surface treatment methods such as coating treatment, printing treatment, adding a wear-resistant layer, or surface composite. Complete the treatment according to the corresponding parameters. After the treatment is completed, check the surface effect to ensure that there are no scratches, no color difference, and no peeling. Step i, cutting: Transfer the surface-treated sheet to the CNC cutting machine. Set the cutting size and cutting path according to the customer's order requirements. After cutting, check the dimensional accuracy through the detection device.

7. The process according to claim 6, characterized in that: In the fiber opening step, the fiber raw materials selected are dry and impurity-free polyester fibers with a length of 38-65mm and a fineness of 1.5-25D, polypropylene fibers with a length of 38-65mm and a fineness of 2.0-25D, and auxiliary fibers with a length of 35-60mm and a fineness of 2.0-20D. The melting point of polyester fibers is 255-260℃, the melting point of polypropylene fibers is 165-175℃, the moisture content of the fiber raw materials is ≤8%, and there are no lumps or oil stains. The opening machine's hand roller speed is 800-1200 r / min, the carding roller speed is 300-500 r / min, and the impurity screening accuracy after opening the fiber raw material is ≥98%.

8. The process according to claim 6, characterized in that: In the fiber blending step, the error in the precise proportioning of fiber raw materials is ≤ ±1wt%; The high-speed mixer has a stirring speed of 500-800 r / min, a mixing time of 15-25 min, a mixing temperature controlled at 0-40℃, and a mixing uniformity of ≥95%.

9. The process according to claim 6, characterized in that: During the carding and web-laying process, the carding machine should rotate at 200-300 rpm with a needle spacing of 5-8 mm. The straightness of the carded fiber monofilaments should be ≥90%. The web-laying speed should be 1-2 m / min. If the fiber web preform enters the high-temperature baking process, a shrinkage allowance of 1.5-2 times should be reserved in the web-laying thickness. The surface density of the fiber web preform should be uniform, with a deviation of ≤±5 g / m. 2 .

10. The process according to claim 6, characterized in that: In the heating and cold pressing forming step, the heating temperature is 100-200℃, the heating time is 3-6min, the conveying speed is 0.5-1.0m / min, and a slight positive pressure is maintained in the drying tunnel, with a pressure of 0.01-0.02MPa, to ensure that the fiber web blank is heated evenly throughout. The cold pressing temperature is 25-35℃, the cold pressing pressure is 2-3MPa, the cold pressing time is 5-8min, the width of the formed stepped thin edge and suspended thin edge is 5-45mm, and the thickness is 1 / 3 to 1 / 2 of the thickness of the main body of the finished board.

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