A method for manufacturing an ultra-matte floor

Abstract

The present application relates to a kind of preparation methods of super-matt floor, the method of the present application includes: providing floor substrate;At the edge of the plate surface of the substrate, arc-shaped chamfer is processed;The surface of the plate surface of the substrate and the arc-shaped chamfer is coated with super-matt excimer paint;Super-matt excimer paint is irradiated using 172nm excimer ultraviolet rays, and its surface layer is instantaneously cured to form micro-crease structure, and super-matt surface is obtained.The arc-shaped chamfer is preferably cut or molded by multi-tooth rotary cutter, and the single-side width is 1.5-2.5mm, and the radius of arc is 4-8mm.The present application is synergized by arc chamfer and super-matt excimer curing process, and the bright line at the joint of floor is completely eliminated, the super-matt effect of 60° glossiness 2-3GU and surface roughness Ra≤0.6μm is realized, the floor is endowed with the delicate touch of baby skin, and the texture at chamfer is continuous and natural, without white or edge collapse, the process is flexible, the yield is high, and it is suitable for high-end manufacturing of PVC stone plastic floor.

Description

Technical Field

[0001] This invention belongs to the field of flooring, specifically relating to a method for preparing ultra-matte flooring. Background Technology

[0002] Over the past two decades, modern home décor styles have undergone significant evolution. Flooring aesthetics have shifted from the early pursuit of high-gloss, eye-catching finishes to a preference for natural textures and understated elegance with lower-gloss finishes. Market research shows that ultra-matte flooring is becoming an important segment of the high-end flooring market, growing at an average annual rate of 15%-20%.

[0003] As an innovative representative in this field, ultra-matte micro-molded flooring combines ultra-matte surface treatment technology with micro-molding process to achieve extremely low light reflectivity and delicate three-dimensional texture, thus preserving the natural texture of wood flooring. This product, which balances natural aesthetics with "low light pollution" characteristics, not only meets the aesthetic needs of modern minimalist and Nordic styles that pursue natural texture and understated luxury, but also aligns with the environmental protection concept of healthy homes.

[0004] Most flooring products on the market currently use a beveled edge design, which has the drawback of creating a bright line at the joint (bevel) when viewed from the side after large-area installation. This invention solves this problem by using rounded bevels and UV-cured finishing processes. Summary of the Invention

[0005] In view of the shortcomings of the prior art, the present invention proposes a method for preparing ultra-matte flooring.

[0006] A method for preparing an ultra-matte floor, comprising the following steps: S100. Provides flooring substrate; S200. A rounded chamfer is formed at at least one edge of the substrate; S300. Apply an ultra-matte excimer paint to the surface of the floor substrate; S400. Irradiate the ultra-matte excimer paint with ultraviolet light to instantly solidify its surface and form a micro-wrinkled structure, thereby obtaining an ultra-matte surface, which is the ultra-matte floor.

[0007] Preferably, in step S200, a multi-tooth rotary cutter is used to cut an arc-shaped chamfer at the edge of the floor substrate.

[0008] Preferably, in step S200, the rounded chamfer is formed by molding with an embossed roller having a rounded chamfer relief during the extrusion process.

[0009] Preferably, the width of one side of the arc-shaped chamfer is 1.5mm to 2.5mm.

[0010] Preferably, the radius of the arc-shaped chamfer is 4mm to 8mm.

[0011] Preferably, the irradiation time of the ultraviolet light is 30 to 50 seconds.

[0012] Preferably, the ultra-matte excimer paint comprises, by weight percentage: Main oligomers: 40%–60%; Active dilution monomer 30%–50%; Functional additives: 1%–5%.

[0013] Preferably, the main oligomer is polyurethane acrylate and / or epoxy acrylate.

[0014] Preferably, the functional additives include leveling agents, defoamers, and adhesion promoters.

[0015] Preferably, the formation step of the flooring substrate includes an extrusion process, and the process parameters of the extrusion process are as follows: The five temperature control sections of the barrel are 190℃, 190℃, 185℃, 180℃, and 175℃ respectively. The mold has seven temperature control levels: 220℃, 220℃, 210℃, 210℃, 201℃, 230℃, and 230℃, respectively. The rolling temperature is 190℃ to 90℃, the rolling speed is 1.5m / min, and the rolling speed ratio is 1:1.1.

[0016] In summary, compared with the prior art, the present invention achieves the following technical effects: 1. Micro-molded texture effect: The beveled corners at the joints of the flooring are rounded and natural, which is more natural and three-dimensional compared with conventional beveled flooring.

[0017] 2. Environmental friendliness: The ultra-matte excimer paint uses low-VOC reactive thinner (mainly acrylic monomers), and the curing process is completed under nitrogen protection to avoid benzene solvent pollution and meet food-grade environmental protection standards, while conventional traditional paints mainly contain benzene / ester organic solvents.

[0018] 3. Matte finish and skin-like feel: Ultra-matte excimer paint has a penetration depth of only 100-500nm (160-190nm, irradiation time 30-50 seconds) under 172nm ultraviolet light, which causes the surface of the coating to solidify instantly to form a micro-wrinkled structure, and the underlying layer to solidify gradually, achieving a matte finish and skin-like feel. Conventional paints achieve a matte effect by adding a large amount of matting agent. Attached Figure Description

[0019] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of the present invention and should not be regarded as a limitation on the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0020] Figure 1 This is a schematic diagram of the structure of a beveled chamfer and a rounded chamfer. Detailed Implementation

[0021] To enable those skilled in the art to better understand the present invention, the technical solutions in the embodiments of the present invention are clearly and completely described. 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 should fall within the scope of protection of the present invention.

[0022] I. Paint Formula Optimizing the formulation of ultra-matte paint is fundamental to ultra-matte finishing. Unlike traditional matte paints, ultra-matte UV paints require special design: on the one hand, they must ensure sufficient fluidity and coverage to facilitate the formation of a uniform coating; on the other hand, the ratio of resin to monomer needs to be adjusted so that the paint film forms an appropriate micro-rough surface structure after curing. Specifically, in the formulation of conventional matte paints, the main components, by weight percentage, include: Main oligomer (hydroxyl acrylic resin): 15%-25%; Solvent (composed of true solvent (butyl acetate, etc.) + co-solvent (butanol) + diluent (xylene): 65%-80%) Matting systems (commonly fumed silica): 3%-8%; Additives: 1%-4%.

[0023] The formulation of this application (hereinafter referred to as excimer paint) uses epoxy acrylate and / or polyurethane acrylate as the main oligomers, combined with reactive diluent monomers and functional additives, to achieve the light scattering effect of the paint film itself without adding traditional matting agents. This formulation avoids the problem of reduced paint film strength caused by adding large amounts of matting agents such as silica.

[0024] The specific excimer paint formulations, by mass fraction, are as follows: Main oligomers: 40% - 60%; Reactive dilution monomer 30% - 50%, Functional additives 1% - 5% The reactive diluent monomer is obtained by compounding highly active multifunctional monomers and low-viscosity monofunctional monomers.

[0025] Functional additives mainly include leveling agents, defoamers, and adhesion promoters.

[0026] II. UV Curing Method Conventional UV paints on the market, which are cured by natural drying or mercury lamp irradiation, cannot create a micro-wrinkle effect.

[0027] The process of this application uses ordinary LED tubes for pre-curing to slightly set the ultra-matte paint; then, under nitrogen protection, 172nm excimer light is used for irradiation, which causes the outermost layer of the paint to instantly cure and shrink, forming a micro-wrinkle effect.

[0028] III. Micro-molding texture technology Option 1: First, extrude and mold the rounded corners, then apply UV coating. This solution is applicable to extrusion production lines with rounded chamfered embossed rollers. The specific steps are as follows: Extrusion process: PVC resin, light calcium carbonate, stabilizer, lubricant, etc. are mixed to 120℃ and discharged. After the mixture is cooled to 75℃, it is placed in the storage silo. The mixture is fed into the twin-screw extruder for extrusion processing through the automatic feeding system. The temperature control of the 5 sections of the barrel is 190℃, 190℃, 185℃, 180℃, and 175℃ respectively. The material enters the mold through the screw, and the mold's seven temperature control settings are sequentially set to 220℃, 220℃, 210℃, 210℃, 201℃, 230℃, and 230℃. The material is extruded through a die and passes through an embossing roller with rounded chamfered relief, directly forming a rounded chamfer on the edge of the substrate. Then it is calendered by five rollers (calendering temperature 190℃→90℃, speed 1.5m / min, speed ratio 1:1.1) and cut to size.

[0029] Front UV process: The extruded sheets are passed through a UV production line and coated with primer (coating amount 10-12g / m²). 2 Mercury lamp curing energy: 150-190 mJ / cm 2 ) and excimer topcoat (coating amount 11-13g / m 2 In this embodiment, the excimer topcoat uses a blend of polyurethane acrylate and epoxy acrylate as the main oligomer. After the topcoat is applied, it is irradiated with 172nm excimer light for 30-50 seconds under nitrogen protection to form a micro-wrinkled structure on the surface of the topcoat, and then deep curing is completed using a mercury lamp.

[0030] Apply a sound-absorbing film to the back: Apply a sound-absorbing film to the UV-coated board.

[0031] Precision cutting: Cut at specific points according to the positioning grooves on the board and groove according to the locking requirements.

[0032] Option 2: First, cut and chamfer the edges, then apply primer and topcoat. This solution is applicable to general extruded sheets. By machining rounded corners through post-extrusion grooving, the defect rate of the extrusion molding process can be significantly reduced. The specific steps are as follows: Extrusion process: Extrude ordinary flat substrate (without chamfer) according to the extrusion parameters in Scheme 1, and cut it for later use.

[0033] First UV coating: The extruded sheets are passed through a UV production line and coated with a primer (coating amount 10-12g / m²). 2 Mercury lamp curing energy: 130-180 mJ / cm 2 This primer contains 40%-60% polyurethane acrylate, 30%-50% reactive diluent monomer, and 1%-5% functional additives (including photoinitiator and alumina abrasion-resistant powder).

[0034] Grooving and chamfering: Grooving is performed according to the locking requirements, while a multi-tooth rotary cutter is used to cut a rounded chamfer on the edge of the plate. The chamfering parameters can be set to a single-sided width of 2mm or 2.5mm, and a radius of R6 or R4.

[0035] The second UV coating: The grooved and rounded corner sheet is passed through the UV production line again, and a second primer coat is applied (similar formula to the first primer coat, but without aluminum oxide), with a coating weight of 10-12 g / m². 2 Mercury lamp curing energy: 150-190 mJ / cm 2 Then apply an excimer topcoat, with a coating weight of 11-13 g / m². 2 In this embodiment, the excimer topcoat uses a blend of polyurethane acrylate and epoxy acrylate as the main oligomer. It is then irradiated with 172nm excimer light for 30-50 seconds under nitrogen protection, and finally completely cured with a mercury lamp.

[0036] Apply a sound-dampening film to the back: Same as Option 1.

[0037] IV. Examples Several embodiments were prepared according to the above formula and method, and the specific parameters are shown in Table 1: Table 1 Parameters of the Example V. Performance Testing and Evaluation The flooring obtained in the examples was evaluated for both appearance and performance.

[0038] 1. Surface roughness (Ra) test The test was conducted using a stylus-type surface roughness measuring instrument (such as the Mitutoyo SJ series).

[0039] According to GB / T 1031 standard, five measurement points were randomly selected on the sample surface (avoiding obvious molding grooves and focusing on planar texture areas). The sampling length L was set to 0.8 mm, and the evaluation length to 4 mm. The arithmetic mean centerline deviation Ra obtained by sliding the probe along the direction perpendicular to the texture was recorded.

[0040] 2. Gloss (GU) Test Referring to GB / T 9754, multiple measurements were taken at the center and four corners of the board using a 60° measuring angle (a common standard angle in the flooring industry). Before testing, the instrument needed to be calibrated using a standard black crystal board, and the average of five readings was taken as the final gloss result.

[0041] 3. Evaluation of tactile effects (sensory and simulation) Blind testing was conducted by five professionally trained quality inspectors, who evaluated the samples by visual inspection and by sliding their fingertips across the surface.

[0042] 4. Evaluation of Micromolding Effect Under a standard light source box (D65 light source), at a distance of 0.5m from the board, visually inspect whether the texture at the chamfer is continuously sunken, and whether there is any "exposed white" or "chipped edge".

[0043] 5. Overall assembly effect evaluation Four or more floorboards are joined together in a cross pattern.

[0044] Observe whether the shape of the rounded chamfer formed by splicing is linear and consistent, and whether there is a "broken groove" phenomenon caused by misalignment of the molding groove.

[0045] 6. Defect Rate Statistical analysis of the defective product ratio for each process route in mass production.

[0046] The test results are shown in Table 2.

[0047] Table 2 Performance Test Results Table 2 shows the results: Comparison of Example 3 (conventional paint + beveling) and Example 4 (excimer paint + beveling): It can be seen that the surface smoothness of the excimer paint is better than that of the conventional matte paint, and the overall effect after assembly is also better than that of the conventional matte paint.

[0048] Comparison of Example 2 (excimer paint + extrusion molding rounded chamfer) and Example 5 (excimer paint + pre-grooved rounded chamfer): Both achieved excellent results, but the defect rate of Scheme 2 corresponding to Example 5 was much lower than that of Example 2, and it had higher production economy.

[0049] Comparison of Example 5 (2mm / R6 arc), Example 6 (2.5mm / R6), and Example 7 (2.5mm / R4): Increasing the chamfer width and decreasing the radius of curvature help improve the continuity of micromolding and eliminate light and dark surfaces, with Example 7 (2.5mm, R4) showing the best results.

[0050] In summary, Example 7 is the best implementation of the present invention, which combines rounded chamfers (2.5mm, R4), excimer paint and 172nm excimer light curing process, and adopts the process route of "grooving first and then applying topcoat", which achieves excellent performance of ultra-low gloss, ultimate touch, no bright lines and continuous texture.

[0051] 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, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A method for preparing an ultra-matte floor, characterized in that, Including the following steps: S100. Provides flooring substrate; S200. A rounded chamfer is formed at at least one edge of the substrate; S300. Apply an ultra-matte excimer paint to the surface of the floor substrate; S400. Irradiate the ultra-matte excimer paint with ultraviolet light to instantly solidify its surface and form a micro-wrinkled structure, thereby obtaining an ultra-matte surface, which is the ultra-matte floor.

2. The preparation method according to claim 1, characterized in that, In step S200, a multi-tooth rotary cutter is used to cut an arc-shaped chamfer at the edge of the floor substrate.

3. The preparation method according to claim 1, characterized in that, In step S200, an arc-shaped chamfer is formed by molding with an embossed roller having a rounded chamfer relief during the extrusion process.

4. The preparation method according to claim 1, characterized in that, The width of one side of the arc-shaped chamfer is 1.5mm to 2.5mm.

5. The preparation method according to claim 1, characterized in that, The radius of the arc-shaped chamfer is 4mm to 8mm.

6. The preparation method according to claim 1, characterized in that, The ultraviolet light irradiation time is 30 to 50 seconds.

7. The preparation method according to claim 1, characterized in that, The ultra-matte excimer paint comprises, by weight percentage: Main oligomers: 40%–60%; Active dilution monomer 30%–50%; Functional additives: 1%–5%.

8. The preparation method according to claim 7, characterized in that, The main oligomer is polyurethane acrylate and / or epoxy acrylate.

9. The preparation method according to claim 1, characterized in that, The functional additives include leveling agents, defoamers, and adhesion promoters.

10. The preparation method according to claim 1, characterized in that, The formation steps of the floor substrate include an extrusion process, and the process parameters of the extrusion process are as follows: The five temperature control sections of the barrel are 190℃, 190℃, 185℃, 180℃, and 175℃ respectively. The mold has seven temperature control levels: 220℃, 220℃, 210℃, 210℃, 201℃, 230℃, and 230℃, respectively. The rolling temperature is 190℃ to 90℃, the rolling speed is 1.5m / min, and the rolling speed ratio is 1:1.1.

Images