Method for preparing cloth grain base short pile leather touch decorative board

Abstract

This invention relates to the field of decorative panel manufacturing technology, and discloses a method for preparing a fabric-textured short-pile leather-feel decorative panel. The method includes: coating a PU slurry onto a releaseable textured protective layer with a textured surface to form a PU suede layer precursor; applying a first adhesive layer to one side of the fabric-textured substrate and hot-rolling it to the PU suede layer precursor to form a suede-textured composite structure with a textured protective layer; applying a second adhesive layer to the side of the fabric layer opposite to the PU suede layer and hot-pressing it to the structural base layer while retaining the textured protective layer; subsequently cooling and shaping, and peeling off the textured protective layer to obtain the finished product. This invention reduces the flattening and loss of the short-pile texture during processing by continuously involving the textured protective layer in the hot-rolling, hot-pressing, and cooling processes. Furthermore, the composite of the PU suede layer and the fabric layer allows the panel to possess both the texture of short-pile leather and the tactile feel of a fabric base, making it suitable for applications such as 3C product exterior decoration, interior finishes, and home décor.

Description

Technical Field

[0001] This invention relates to the field of decorative panel preparation technology, specifically a method for preparing a fabric-textured short-pile leather-feel decorative panel. Background Technology

[0002] With the development of 3C product exterior decoration, interior wall decoration, and home furnishing materials, decorative panels are no longer just about surface color and pattern effects. The tactile texture, surface smoothness, texture stability, and overall flexibility of the material are also gradually becoming important factors in product design. Fabric-textured decorative panels, due to their regular woven texture, can present a visual and tactile effect similar to a woven mesh, and have been applied in various decorative scenarios.

[0003] However, existing fabric-textured PU decorative panels typically feature a fabric mesh texture, resulting in a relatively simple surface feel that fails to simultaneously replicate the delicate and smooth texture of leather suede. Furthermore, during the lamination, hot-pressing, and subsequent molding processes of the PU layer and fabric substrate, the surface suede texture is easily affected by pressure, friction, or adsorption, leading to issues such as pile flattening, texture loss, and uneven distribution. This results in an unstable surface texture in the finished product, making it difficult to achieve a harmonious composite feel between the fabric texture and the suede surface.

[0004] Therefore, there is an urgent need for a method to prepare a fabric-textured short-pile leather-feel decorative panel. This method would retain the regular texture and tactile feel of the fabric-textured substrate, introduce a short-pile leather-feel layer, and reduce the damage to the pile texture during processing through reasonable texture protection, interlayer composite, and cooling release processes, thereby improving the surface tactile feel and molding stability of the decorative panel.

[0005] A search revealed a Chinese patent document that discloses a textured coated fabric and its preparation process [Application No.: 202410137155.3, Publication No.: CN117702504B]. The technical solution involves the preparation of coated fabrics by compounding an adhesive coating and a top coating on the surface of a base fabric, and then pressing and rolling it in a semi-cured, soft, and plastic state to make the surface of the top coating exhibit a texture consistent with that of the base fabric.

[0006] While the comparative patent achieves the goal of presenting a base fabric texture on the coating surface, featuring the formation of surface texture through PU coating, base fabric lamination, and pressing processes, this invention employs a continuous lamination process of a PU short pile layer with a textured protective layer, a fabric-textured substrate, and a structural base layer. The textured protective layer is retained during hot roller bonding, hot pressing, and cooling and shaping, and then peeled off after shaping, thus protecting the short pile texture during subsequent processing. Furthermore, this invention emphasizes the matching relationship between the pile crown height of the PU suede layer and the characteristic height of the fabric texture layer, enabling the board to possess both the delicate touch of short pile leather and the feel of a fabric base. In contrast, the comparative patent primarily focuses on the emergence of a base fabric texture on the coating surface and does not possess the technical features of the short pile leather feel layer, the delayed release with a protective layer, and the lamination of the decorative board's structural base layer as described in this invention. Summary of the Invention

[0007] In view of the problems existing in the prior art, the purpose of this invention is to provide a method for preparing a decorative panel with a fabric-textured short-pile leather feel.

[0008] A method for preparing a fabric-textured short-pile leather-feel decorative panel, characterized by comprising the following steps: S1. Apply PU paste onto a releaseable textured protective layer with a textured surface to form the first composite layer; S2. Apply a first adhesive layer to one side of the fabric substrate and roll it with the PU suede layer precursor in the first composite layer to form a second composite layer consisting of a textured protective layer, a PU suede layer, a first adhesive layer and a fabric layer. S3. Apply a second adhesive layer to the side of the fabric layer that is away from the PU suede layer, and hot-press it together with the structural base layer while retaining the textured protective layer to form a composite board with a textured protective layer. S4. After cooling and shaping the composite board with the textured protective layer, peel off the textured protective layer to obtain a fabric-textured short-pile leather-like decorative board. The pile crown height of the PU suede layer is not less than the fabric texture feature height of the fabric texture layer.

[0009] Preferably, the textured protective layer is textured paper, one side surface of the textured paper is the textured surface, and the PU paste is coated on the textured surface.

[0010] The above technical solution enables PU paste to form a velvety base on the surface of textured paper, and protects the short pile texture on the surface of the PU velvety layer during subsequent lamination. The textured paper can both support the PU paste and is easy to peel off after the board has cooled and set, which helps to reduce the impact of the release process on the pile morphology.

[0011] Specifically, the textured surface of the textured paper can directly contact the PU slurry, allowing the PU slurry to acquire the corresponding surface texture during the molding process. At the same time, compared with the processing method of directly contacting the pressing parts, the textured paper can form an isolation layer on the outside of the PU velvet layer, reducing the direct effect of external pressure and friction on the short pile texture during hot roller bonding and hot pressing.

[0012] In practical applications, using textured paper as a texture protection layer can take into account the needs of texture forming, process protection and subsequent release, making it easier to maintain the short-pile leather texture on the surface of the finished product and helping to improve the surface consistency of different batches of decorative panels.

[0013] Preferably, the textured protective layer is one of a PET layer, a silicone layer, or a release paper layer, and one side surface of the PET layer, silicone layer, or release paper layer has the textured surface.

[0014] The above technical solutions allow for the selection of appropriate textured protective layer materials based on different processing conditions and product requirements, ensuring a stable texture-bearing foundation for the PU suede layer during molding and lamination. PET layers, silicone layers, or release paper layers can all form textured surfaces and can work in conjunction with PU paste to complete the surface texture formation.

[0015] Specifically, different textured protective layer materials differ in terms of sheet stability, flexibility, and release properties. The PET layer has good morphological stability, the silicone layer has a certain degree of flexibility, and the release paper layer has good peelability. After setting one side of each material as a textured surface, they can all serve as the coating surface for PU paste and cover the outside of the PU suede layer in subsequent lamination processes.

[0016] In practical applications, the availability of various optional textured protective layer materials allows the preparation method to be adapted to different equipment conditions and sheet specifications, facilitating selection based on the surface texture of the finished product, processing conditions, and release requirements, thereby improving the flexibility of the process application.

[0017] Preferably, in step S1, the textured protective layer is in direct contact with the PU suede layer precursor; before the cooling and shaping are completed in steps S2 to S4, the textured protective layer is in direct contact with the PU suede layer; after the textured protective layer is peeled off in step S4, the textured protective layer is separated from the PU suede layer.

[0018] The above technical solution clarifies the positional relationship of the textured protective layer in different process stages, ensuring that the textured protective layer is retained from the PU slurry coating stage to the cooling and setting stage, and then separated from the PU suede layer after the board is formed. This arrangement helps maintain the integrity of the short pile texture during the composite processing.

[0019] Specifically, in step S1, the textured protective layer is in direct contact with the PU suede precursor, allowing the PU slurry to adhere to the textured surface and form a surface structure. Before the cooling and setting are completed in steps S2 to S4, the textured protective layer continues to be in direct contact with the PU suede, ensuring that the outer side of the PU suede is always covered. After the textured protective layer is peeled off in step S4, the short pile texture is exposed on the surface of the finished product.

[0020] In practical applications, this phased retention and separation method can prevent the PU suede surface from being exposed to the external processing environment too early, reduce the direct impact of the pressing parts on the suede, and make it easier for the surface of the finished board to retain both the short pile texture and the fabric-textured base feel at the same time.

[0021] Preferably, the fabric texture feature height of the fabric texture layer is 50 μm, and the pile crown height of the PU suede layer is 60 μm.

[0022] The above technical solution allows the height of the short pile texture in the PU suede layer to be slightly higher than the height of the fabric texture feature in the fabric layer, thereby reducing the obscuring of the short pile texture by the fabric mesh. This height relationship is beneficial for the short pile leather texture and the fabric base feel to be presented together on the same surface.

[0023] Specifically, when the fabric texture feature height of the fabric layer is 50μm, if the pile crown height of the PU suede layer is lower than this height, the undulation of the fabric mesh tends to dominate the surface feel, resulting in insufficient three-dimensionality of the short pile texture. However, when the pile crown height of the PU suede layer is set to 60μm, the short pile texture can form a more obvious surface morphology on the fabric base without completely obscuring the mesh feel of the fabric layer.

[0024] In practical applications, this high degree of matching can improve the tactile texture of the finished board surface, making it different from single-textured decorative boards and ordinary PU decorative boards, and more suitable for decorative scenarios that require surface texture and tactile texture.

[0025] Preferably, the adhesives in the first adhesive layer and the second adhesive layer are one of hot melt adhesive, pressure-sensitive adhesive, polyurethane adhesive, epoxy adhesive or modified acrylic adhesive; the first adhesive layer is located between the PU suede layer and the textured layer, and the second adhesive layer is located between the textured layer and the structural base layer.

[0026] The above technical solution enables a stable interlayer composite relationship to be formed between the PU suede layer, the fabric texture layer, and the structural base layer. The first and second adhesive layers are respectively located at different interlayer positions, allowing the functional layers to combine in a predetermined order to form a complete decorative panel structure.

[0027] Specifically, the first adhesive layer is located between the PU suede layer and the textured layer, enabling the PU suede layer and the textured layer to bond together; the second adhesive layer is located between the textured layer and the structural base layer, enabling the textured layer and the structural base layer to bond together. Different types of adhesives can be selected according to the surface characteristics of the materials, the composite conditions, and the requirements for the finished product, in order to adapt to the bonding needs between different interlayer materials.

[0028] In practical applications, the double adhesive layer design makes the composite relationship between the PU suede layer, the fabric texture layer and the structural base layer clearer. This not only helps maintain the short pile texture and fabric feel of the outer layer, but also helps the finished board to have the corresponding structural support and processing adaptability.

[0029] Preferably, the textured substrate is a regularly woven fiber layer, and the regularly woven fiber layer forms the textured layer after step S2; the structural base layer is one of PC board, composite board, wood board or marble board.

[0030] The above technical solution enables the formation of a textured layer through regularly woven fiber layers, and provides a supporting foundation for the decorative panel through a structural base layer. The textured layer and the structural base layer each perform different structural functions, giving the finished panel both a textured surface and superior performance characteristics.

[0031] Specifically, the regularly woven fiber layer has a relatively stable weave texture. In step S2, it is combined with the PU suede layer to form a textured layer, which is located between the PU suede layer and the structural base layer. Room-temperature solid boards such as PC boards, composite boards, wood boards, or marble slabs can serve as the structural base layer, forming the main body of the board after being combined with the textured layer. The combination of these two materials gives the decorative board both the textured base provided by the textured substrate and the supporting performance provided by the structural base layer.

[0032] In practical applications, this material combination allows the preparation method to be adapted to different decorative scenarios. For example, PC boards or composite boards can be used in the exterior decoration of 3C products, while wood boards, composite boards, or marble boards can be used in interior or home decoration, thereby expanding the application range of the finished boards.

[0033] Preferably, the fabric-textured short-pile leather-feel decorative panel obtained in step S4 comprises, from the outside to the inside, a PU suede surface layer, a first adhesive layer, a fabric texture layer, a second adhesive layer, and a structural base layer. The PU suede surface layer has a short-pile texture on the side facing away from the fabric texture layer, and the structural base layer is a room-temperature solid panel.

[0034] The above technical solution clarifies the final layered structure of the finished decorative panel, allowing the PU suede layer, textured layer, and structural base layer to be combined in a sequence from the outside in. This structure creates a cohesive whole where the tactile surface, textured base, and panel support components work together seamlessly.

[0035] Specifically, the PU suede layer is located on the outermost side, with a short pile texture on the side facing away from the fabric texture layer; the first adhesive layer is located between the PU suede layer and the fabric texture layer, the fabric texture layer is located between the PU suede layer and the structural base layer, the second adhesive layer is located between the fabric texture layer and the structural base layer, and the structural base layer is located on the inner side and uses a room-temperature solid board. This layered arrangement ensures that the short pile texture is on the finished surface, the fabric texture layer is below it to form the texture base, and the structural base layer is located on the inner side to form support.

[0036] In practical applications, this layered structure allows for a good balance between surface feel, texture, and structural support in the finished product. The finished product can be cut, laminated, or installed according to the application scenario, making it suitable for 3C product exterior decoration, interior finishing, and home décor.

[0037] Compared with the prior art, the present invention has the following advantages: 1. This invention retains a textured protective layer after the PU suede surface layer is formed, allowing it to participate in subsequent hot roller bonding, hot pressing, and cooling and setting processes. This reduces the direct impact of pressure, friction, or contact adsorption on the short pile texture during processing. Cooling and setting before release helps maintain the pile shape, resulting in a finished product surface that better exhibits the texture of short pile leather.

[0038] 2. This invention combines a PU suede layer, a fabric texture layer, an adhesive layer, and a structural base layer, matching the pile height of the PU suede layer with the fabric texture height of the fabric texture layer, allowing the short pile texture and the tactile feel of the fabric base to coexist. The resulting board retains the layered feel of the fabric material while possessing a soft and delicate surface texture, making it suitable for various decorative scenarios. Attached Figure Description

[0039] Figure 1 These are confocal analysis diagrams of different textured hairs and their crown heights according to the present invention; Figure 2 These are comparison images of the morphology of the same texture under different processing techniques according to the present invention. Figure 3 This is a schematic diagram of the layered structure of the fabric-textured short-pile leather-feel decorative panel of the present invention; Figure 4 This is a flowchart illustrating the manufacturing process of the fabric-textured short-pile leather-feel decorative panel of the present invention. Detailed Implementation

[0040] The present invention will be further described below with reference to the accompanying drawings and specific embodiments. It should be understood that the following embodiments are for illustrative purposes only and are not intended to limit the scope of protection of the present invention. All equivalent substitutions, improvements, and variations made within the spirit and principles of the present invention should fall within the scope of protection of the present invention.

[0041] The present invention provides a method for preparing a fabric-textured short-pile leather-feel decorative panel, which is not simply a matter of bonding a PU layer, a fabric layer and a structural base layer in sequence, but rather focuses on the process design of maintaining the short-pile texture during the composite process and the synergistic presentation of the short-pile feel and the fabric texture feel.

[0042] Existing fabric-textured PU decorative panels typically rely on the regular grid structure of the fabric substrate itself as the primary source of tactile texture. While this structure can create a certain fabric-like feel, the surface texture is relatively simple and cannot simultaneously replicate the delicate and soft texture of leather suede. If a PU suede layer is directly laminated onto the fabric substrate, during subsequent hot roller bonding, hot pressing, or molding processes, the PU suede layer is easily subjected to the pressure and friction of rollers, pressure plates, molds, or other contact surfaces, leading to flattened pile, smoothed texture, localized sparseness, or loss of suede texture. Especially when the fabric layer itself has a raised and recessed grid structure, the fabric grid can easily protrude excessively on the finished surface, making it difficult to stably retain the suede texture.

[0043] To address the aforementioned issues, this invention employs a delayed release process with a textured protective layer. Specifically, PU slurry is first applied to a releaseable textured protective layer with a textured surface to form a first composite layer. Then, a first adhesive layer is applied to one side of the fabric-textured substrate, and the PU suede layer precursor in the first composite layer is hot-rolled bonded to the first adhesive layer to form a second composite layer consisting of the textured protective layer, the PU suede layer, the first adhesive layer, and the fabric texture layer. Next, a second adhesive layer is applied to the side of the fabric texture layer away from the PU suede layer, and the textured protective layer is hot-pressed onto the structural base layer while still covering the outside of the PU suede layer to form a composite board with a textured protective layer. Finally, after the composite board with the textured protective layer is cooled and shaped, the textured protective layer is peeled off to obtain a fabric-textured short-pile leather-feel decorative board.

[0044] In this invention, the textured protective layer does not only serve a load-bearing function during the PU coating stage, nor is it immediately peeled off after the initial formation of the PU suede layer. Instead, it remains continuously on the outside of the PU suede layer during the hot roller bonding in step S2, the hot pressing in step S3, and the cooling and setting in step S4. Therefore, when the PU suede layer is laminated with the fabric layer and structural base layer, the outer surface of the PU suede layer is not directly exposed to the pressing contact surface, reducing the impact of processing pressure, friction, and contact adhesion on the short pile texture. Demolding after the board has cooled and set allows the short pile texture on the surface of the PU suede layer to be retained in a more complete state on the finished product's appearance.

[0045] like Figure 1 As shown, Figure 1 Confocal analysis images of different textured hairs and their crown heights. Among them, Figure 1a) is the short-pile texture morphology diagram, b) is the short-pile crown height analysis diagram, c) is the long-pile texture morphology diagram, and d) is the long-pile crown height analysis diagram. Figure 1 It can be seen that the height of the pile crown directly affects the appearance of the suede texture on the fabric base. When the pile crown height is low, the surface undulation of the suede texture is insufficient and is easily affected by the height of the fabric layer's own grid, resulting in an indistinct short pile texture. When the pile crown height is increased, the three-dimensionality and recognizability of the suede texture are enhanced, and a clearer short pile leather feel can be formed on the fabric base.

[0046] Furthermore, analyzing the fabric texture feature height of the fabric layer, when the fabric texture feature height is 50μm and the pile crown height of the PU suede layer is 40μm, the pile crown height is lower than the fabric texture feature height, making the grid undulations of the fabric layer more likely to dominate the finished product surface, and the short pile texture is difficult to fully display. When the pile crown height of the PU suede layer is 60μm, the pile crown height is higher than the fabric texture feature height, and the short pile texture can maintain a more obvious three-dimensional shape on the fabric base. Therefore, this invention ensures that the pile crown height of the PU suede layer is not less than the fabric texture feature height of the fabric layer, so that the tactile feel of the short pile leather and the tactile feel of the fabric base can be presented synergistically.

[0047] like Figure 2 As shown, Figure 2 These are comparison images of the pile morphology of the same texture under different processing techniques. Figure 2 In Figure a), the morphology of the fluff formed under the traditional processing method is shown, and in Figure b), the morphology of the fluff formed under the improved processing method of this invention is shown. Figure 2 As can be seen from a), in the traditional processing method, the PU suede layer is easily affected by external pressure, friction or contact adsorption during the subsequent composite process, which causes the pile to lie flat, be flattened or lose texture. The pile texture of the finished product is significantly weakened, the grid features of the fabric layer are relatively prominent, and the overall touch is closer to the touch of a single fabric texture.

[0048] Depend on Figure 2 As can be seen from b) in the improved processing method of this invention, the texture protective layer is always retained on the outer side of the PU suede layer during hot roller bonding, hot pressing, and cooling and shaping. The texture protective layer is then peeled off after the entire board has cooled and shaped. Since the PU suede layer is not directly exposed to the pressing contact surface during the bonding process, the suede texture is isolated and protected by the texture protective layer, the suede shape is more complete, the short pile texture is more obvious, and the grid features of the fabric layer and the short pile texture of the PU suede layer can be presented together.

[0049] like Figure 3As shown, the present invention forms a composite structure in the preparation process consisting of a textured protective layer, a PU suede layer, a first adhesive layer, a fabric texture layer, a second adhesive layer, and a structural base layer stacked sequentially. The textured protective layer is located outside the PU suede layer and is not immediately peeled off during preparation; instead, it enters the hot-pressing and cooling / setting stage together with the PU suede layer, fabric texture layer, and structural base layer. The PU suede layer forms the finished product's tactile surface. The first adhesive layer is located between the PU suede layer and the fabric texture layer, the fabric texture layer is located between the PU suede layer and the structural base layer, and the second adhesive layer is located between the fabric texture layer and the structural base layer. The structural base layer forms the board support layer. After cooling and setting, the textured protective layer is peeled off from the surface of the PU suede layer to obtain the final decorative board.

[0050] like Figure 4 As shown, the preparation process of this invention includes: firstly, coating a PU slurry onto the textured surface of a textured protective layer to form a first composite layer; then, hot-rolling the PU suede precursor in the first composite layer to a fabric-textured substrate with a first adhesive layer applied to it to form a second composite layer; subsequently, applying a second adhesive layer to the back of the fabric-textured layer and hot-pressing it with the structural base layer while retaining the textured protective layer to form a composite board with a textured protective layer; finally, cooling and shaping the composite board with the textured protective layer, and after shaping, peeling off the textured protective layer to obtain a fabric-textured short-pile leather-feel decorative board. The key to this process is that the textured protective layer is not peeled off immediately after the PU suede layer is formed, but is retained until after the structural base layer is laminated and cooled and shaped, thereby reducing the damage to the short-pile texture caused by subsequent processing.

[0051] The decorative panel produced by this invention comprises, from the outside in, a PU suede layer, a first adhesive layer, a fabric texture layer, a second adhesive layer, and a structural base layer. The PU suede layer forms the surface for contact with the material, the fabric texture layer forms the fabric texture base structure, and the structural base layer provides support for the panel. The first adhesive layer is located between the PU suede layer and the fabric texture layer, and the second adhesive layer is located between the fabric texture layer and the structural base layer. Through the combination of the above structure and process, the finished panel can possess both the tactile feel of short-pile leather and the tactile feel of a fabric texture base, distinguishing it from simple fabric texture panels and ordinary PU leather laminate panels.

[0052] The decorative panels produced by this invention can be cut, laminated, embedded, or fixed according to the size and shape of the target product during use. When used for the exterior decoration of 3C products, they can be processed into outer shell decorative sheets, back cover decorative sheets, or protective shell surface materials; when used for interior decoration, they can be used as wall cladding panels or partial decorative panels; when used for home cladding, they can be used as surface materials for cabinet doors, door panels, or furniture exteriors. In use, the PU suede layer serves as the external touch surface, the structural base layer serves as the support surface or mounting surface, and the textured layer is located between the two and participates in the formation of the finished product's tactile feel.

[0053] Example 1: Complete Preparation Example of Delayed Release with Textured Protective Layer This embodiment illustrates the complete preparation process of the present invention, focusing on the continuous retention of the textured protective layer during hot roller bonding, hot pressing, and cooling and shaping processes.

[0054] First, textured paper with a textured surface is selected as the textured protective layer. PU paste is evenly coated on the textured surface of the textured paper, so that the PU paste adheres to the textured surface and forms a PU suede layer precursor, resulting in a first composite layer composed of the textured protective layer and the PU suede layer precursor stacked together.

[0055] Then, a regularly woven fiber layer is selected as the fabric texture substrate, and an adhesive is applied to one side of the fabric texture substrate to form a first adhesive layer. The side of the PU suede layer precursor in the first composite layer that is away from the texture protective layer is stacked with the first adhesive layer and hot-rolled to form the PU suede layer precursor into a PU suede layer, resulting in a second composite layer consisting of a texture protective layer, a PU suede layer, a first adhesive layer, and a fabric texture layer stacked sequentially.

[0056] Subsequently, an adhesive is applied to the side of the textured layer facing away from the PU suede layer in the second composite layer to form a second adhesive layer. The second adhesive layer is then laminated with the structural base layer, and hot-pressed while the textured protective layer remains on the outside of the PU suede layer to form a composite board with a textured protective layer.

[0057] After hot-pressing, the textured protective layer is not immediately peeled off. Instead, the composite board with the textured protective layer is cooled and shaped. After the composite state between the PU suede layer, the fabric layer, the first adhesive layer, the second adhesive layer, and the structural base layer has stabilized, the textured protective layer is peeled off from the surface of the PU suede layer to obtain a fabric-textured short-pile leather-feel decorative board.

[0058] The decorative panel obtained in this embodiment comprises, from the outside to the inside, a PU suede layer, a first adhesive layer, a textured layer, a second adhesive layer, and a structural base layer. The PU suede layer has a short pile texture on the side facing away from the textured layer, the textured layer has a regular textured grid structure, and the structural base layer is a room-temperature solid board. The first and second adhesive layers can be made of hot melt adhesive, pressure-sensitive adhesive, polyurethane adhesive, epoxy adhesive, or modified acrylic adhesive, respectively. The structural base layer can be made of PC board, composite board, wood board, or marble slab.

[0059] The key feature of this embodiment is that the textured protective layer is not immediately peeled off after the initial molding of the PU suede surface layer, but is retained until after the structural base layer is hot-pressed and cooled for setting. Through this process sequence, the PU suede surface layer does not directly contact the pressed components during subsequent lamination processes. The short-pile texture is isolated by the textured protective layer, reducing pile flattening, texture compression, and localized damage. The final board surface not only retains the short-pile leather feel of the PU suede surface layer but also exhibits the fabric-textured base feel through the fabric layer, thus creating a composite tactile experience.

[0060] Example 2: Comparison of Delayed Release Process and Pre-release Process This embodiment illustrates the effect of retaining the texture protective layer until it cools and sets before peeling it off on the retention of the short pile texture.

[0061] The first sample and the second sample were prepared using the same PU slurry, the same textured substrate, the same adhesive, and the same structural base layer.

[0062] The first sample was prepared using the delayed release process of this invention. Specifically, PU slurry was applied to the textured surface of the textured protective layer to form a first composite layer; then, the PU suede precursor in the first composite layer was bonded to the fabric substrate using a first adhesive layer via hot roller bonding to form a suede-textured composite structure with a textured protective layer; finally, the fabric layer was hot-pressed onto the structural base layer via a second adhesive layer on the back side. During the hot roller bonding, hot-pressing, and cooling / setting processes, the textured protective layer remained on the outside of the PU suede layer and was peeled off after the board had cooled and set.

[0063] The second sample adopted a release-molding followed by lamination process. Specifically, PU paste was applied to the textured surface of the textured protective layer to form the first composite layer; after the PU suede layer was initially formed, the textured protective layer was peeled off from the surface of the PU suede layer to directly expose the short pile texture of the PU suede layer; then the exposed PU suede layer was laminated with the fabric substrate and the structural base layer.

[0064] The surface conditions of the first and second samples were observed. In the first sample, the PU suede layer was consistently covered by the textured protective layer during hot roller bonding, hot pressing, and cooling, maintaining a relatively intact short pile texture. The surface pile did not easily flatten, and the finished surface simultaneously exhibited both short pile texture and fabric mesh layers. In the second sample, because the PU suede layer was exposed during subsequent lamination, the surface pile was more susceptible to direct pressure and friction from the pressing components. The pile morphology was more easily flattened or damaged, and the finished surface more likely to show a state where the fabric mesh was prominent while the short pile texture was weakened.

[0065] This embodiment illustrates that, within the same material system, the difference in this invention lies not in simply using a release material to support the PU slurry, but in extending the textured protective layer until after hot-pressing and cooling before peeling it off. This process sequence allows the PU suede layer to remain covered during the lamination process, thereby improving the retention of the short-pile texture in subsequent processing. This feature corresponds to... Figure 2 The differences in forming between traditional processing methods and improved processing methods.

[0066] Example 3: Example of matching the height of the pile crown with the fabric texture. This embodiment illustrates the matching relationship between the pile crown height of the PU suede layer and the fabric texture feature height of the fabric texture layer.

[0067] Decorative panels were prepared using the delayed release process described in Example 1, wherein the textured layer used a textured substrate with a regular grid structure, and the texture feature height of the textured layer was 50 μm. Third and fourth samples were prepared respectively.

[0068] In the third sample, the pile height of the PU suede layer was 40μm. Because this pile height is lower than the characteristic height of the fabric texture layer, the grid undulations of the fabric texture layer are more likely to dominate the finished product surface, resulting in relatively insufficient three-dimensionality and recognizability of the short pile texture on the fabric base. The surface feel of this sample is more like the texture of a fabric grid, lacking the sufficiently delicate feel of short pile leather.

[0069] In the fourth sample, the pile height of the PU suede layer is 60μm. Since this pile height is not less than the characteristic height of the fabric texture layer, the short pile texture can maintain a relatively obvious surface morphology and tactile layering on the fabric base, and the grid structure of the fabric layer will not completely obscure the short pile effect of the PU suede layer. The surface of this sample can simultaneously present the tactile feel of a fabric base and the tactile feel of short pile leather.

[0070] This embodiment illustrates that the present invention does not simply laminate a PU layer onto the surface of a fabric-textured substrate. Instead, it achieves synergy between the short pile texture and the fabric texture mesh structure by controlling the relationship between the pile height of the PU suede layer and the fabric texture feature height. Specifically, when the fabric texture feature height is 50 μm, setting the pile height of the PU suede layer to 60 μm allows the short pile texture to achieve a clearer representation on the fabric-textured substrate. This feature corresponds to… Figure 1 A comparison of the morphology and texture of downy hairs of different crown heights.

[0071] As can be seen from the above embodiments, the technical contributions of this invention are mainly reflected in two aspects: first, the textured protective layer is continuously retained during the composite process of the PU suede layer, the fabric texture layer, and the structural base layer, and is peeled off after cooling and setting; second, the height of the pile crown of the PU suede layer is not less than the height of the fabric texture feature of the fabric texture layer. These two aspects work together to enable the finished board to maintain the short pile texture while presenting the tactile feel of a fabric base, thereby improving the tactile quality and surface texture stability of the decorative board.

[0072] 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.

[0073] 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.

[0074] The above description is merely a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A method for preparing a decorative panel with a fabric-textured short-pile leather feel, characterized in that, Includes the following steps: S1. Apply PU paste onto a releaseable textured protective layer with a textured surface to form the first composite layer; S2. Apply a first adhesive layer to one side of the fabric substrate and roll it with the PU suede layer precursor in the first composite layer to form a second composite layer consisting of a textured protective layer, a PU suede layer, a first adhesive layer and a fabric layer. S3. Apply a second adhesive layer to the side of the fabric layer that is away from the PU suede layer, and hot-press it together with the structural base layer while retaining the textured protective layer to form a composite board with a textured protective layer. S4. After cooling and shaping the composite board with the textured protective layer, peel off the textured protective layer to obtain a fabric-textured short-pile leather-like decorative board. The pile crown height of the PU suede layer is not less than the fabric texture feature height of the fabric texture layer.

2. The method for preparing the fabric-textured short-pile leather-feel decorative panel according to claim 1, characterized in that, The textured protective layer is textured paper, one side of which is the textured surface, and the PU paste is coated on the textured surface.

3. The method for preparing the fabric-textured short-pile leather-feel decorative panel according to claim 1, characterized in that, The textured protective layer is one of a PET layer, a silicone layer, or a release paper layer, and one side surface of the PET layer, silicone layer, or release paper layer has the textured surface.

4. The method for preparing the fabric-textured short-pile leather-feel decorative panel according to claim 1, characterized in that, In step S1, the textured protective layer is in direct contact with the PU suede layer precursor; before the cooling and shaping are completed in steps S2 to S4, the textured protective layer is in direct contact with the PU suede layer; after the textured protective layer is peeled off in step S4, the textured protective layer is separated from the PU suede layer.

5. The method for preparing the fabric-textured short-pile leather-feel decorative panel according to claim 1, characterized in that, The fabric texture feature height of the fabric texture layer is 50μm, and the pile crown height of the PU suede layer is 60μm.

6. The method for preparing the fabric-textured short-pile leather-feel decorative panel according to claim 1, characterized in that, The adhesives in the first adhesive layer and the second adhesive layer are respectively one of hot melt adhesive, pressure-sensitive adhesive, polyurethane adhesive, epoxy adhesive or modified acrylic adhesive; the first adhesive layer is located between the PU suede layer and the textured layer, and the second adhesive layer is located between the textured layer and the structural base layer.

7. The method for preparing the fabric-textured short-pile leather-feel decorative panel according to claim 1, characterized in that, The textured substrate is a regularly woven fiber layer, which forms the textured layer after step S2; the structural base layer is one of PC board, composite board, wood board or marble board.

8. The method for preparing the fabric-textured short-pile leather-feel decorative panel according to claim 1, characterized in that, The fabric-textured short-pile leather-feel decorative panel obtained in step S4 comprises, from the outside to the inside, a PU suede surface layer, a first adhesive layer, a fabric texture layer, a second adhesive layer, and a structural base layer. The PU suede surface layer has a short-pile texture on the side facing away from the fabric texture layer, and the structural base layer is a room-temperature solid panel.

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