Flame-retardant composite decorative plate with natural stone texture

Abstract

The utility model belongs to the technical field of decorative plates, and particularly discloses a flame-retardant composite decorative plate with natural stone textures. The flame-retardant composite decorative plate comprises a core plate, flame-retardant adhesive layers arranged on the two opposite sides of the core plate, and refractory fiber layers arranged on the outer sides of the flame-retardant adhesive layers. Texture grooves are formed in the outer surface of the refractory fiber layer, and real stone paint layers are further arranged on the outer surface, without the texture grooves, of the refractory fiber layer and the inner walls of the texture grooves. According to the flame-retardant composite decorative board, the core board is combined with the refractory fiber layer, the advantages of a wood core board and a fiber cement board type surface board are fully utilized, the stone characteristic of a magnesium cementing material is combined with the wood fiber characteristic, and the texture grooves are formed in the refractory fiber layer; the obtained board has wood texture and strong flame retardant property, and the simulated stone texture effect is better.

Description

Technical Field

[0001] This utility model belongs to the field of decorative panel technology, specifically, it relates to a fire-retardant composite decorative panel with natural stone texture. Background Technology

[0002] Conventional fir core ecological boards are widely praised in the domestic market and are generally used as wall decoration boards and furniture boards. For multi-layer solid wood substrates, the evaluation criteria are first and foremost thickness and layering. Good substrates are characterized by uniform thickness, good layering, no voids or overlaps, and a smooth, flat surface without bulges. Their various physical and chemical properties are superior to those of particleboard and multi-layer boards.

[0003] To achieve flame-retardant properties, existing eco-friendly boards inevitably require the addition of wood flame retardants. This not only increases material costs but also affects the board's mechanical properties to some extent. Furthermore, most wood flame retardants are hygroscopic; after absorbing moisture, they can leach out and come into contact with metal components such as light steel keels, causing corrosion and leading to numerous after-sales problems.

[0004] Furthermore, in the wood-based panel industry, it is currently rare to achieve the texture of stone on the surface of wood-based panels. Stone veneer paper is generally used to replicate the texture of stone. Most eco-friendly panels on the market use melamine paper or PVC as the veneer layer. However, this type of veneer layer has several drawbacks: 1) It adheres to the surface of the eco-friendly panel using organic adhesives, thus releasing a certain amount of formaldehyde; 2) This type of veneer layer is prone to peeling off when exposed to water, leading to reduced surface bonding strength; and 3) The thickness of this type of veneer layer is generally between 10 and 35 microns, so its texture depth is generally controlled to a shallower 5 to 15 microns, resulting in a slightly inferior texture and tactile feel. It still cannot simulate the texture and feel of natural stone, nor does it possess the tactile quality of stone.

[0005] In conclusion, continuous improvement of decorative panels is still needed to promote the development of the industry. Utility Model Content

[0006] To address the problems of poor surface finish, high cost due to the addition of flame retardants, impact on mechanical properties and moisture absorption / corrosion, and surface layer contamination in existing decorative panels and related technologies, this invention provides a novel fire-retardant composite decorative panel with a natural stone texture. This fire-retardant composite decorative panel possesses numerous advantages, including excellent fire resistance, non-corrosiveness, water and moisture resistance, and a superior surface finish.

[0007] The present invention specifically adopts the following technical solution:

[0008] A fire-retardant composite decorative panel with natural stone texture includes a core board, flame-retardant adhesive layers disposed on opposite sides of the core board, and a fire-resistant fiber layer disposed on the outside of the flame-retardant adhesive layers; wherein the outer surface of the fire-resistant fiber layer has textured grooves, and the outer surface of the fire-resistant fiber layer without textured grooves and the inner wall of the textured grooves are also covered with a real stone paint layer.

[0009] The “outer side” mentioned above refers to the side of the flame-retardant adhesive layer and fire-resistant fiber layer that is away from the core board.

[0010] The core board can be a solid wood core board formed by gluing solid wood boards together with the grain aligned and then pressing them together. The material is mostly selected from fir or mixed wood; it can also be any other material that can be used as the solid wood core board in multi-layer decorative panels according to existing technology. At the same time, its thickness and size can adopt any conventional settings in existing technology. For example, the thickness can generally be 5.8mm, 8.8mm or 11.8mm, and the size can generally be 1280mm*2480mm, 1220mm*2440mm or 1280mm*2880mm, etc., which will not be listed here.

[0011] The thickness of the refractory fiber layer should be controlled between 2.6 mm and 3.0 mm. The refractory fiber layer is a structural layer that combines flame retardancy and fiber properties, formed by mixing small wood shavings or small fiber sheets (generally 20-60 mesh) with magnesium cementitious materials and hot pressing.

[0012] Magnesium cementitious materials are commonly used inorganic adhesives in particleboard. They can generally be magnesium oxychloride cement, magnesium oxysulfide cement, magnesium phosphate cement, or conventionally modified magnesium cementitious materials. Compared with organic adhesives, they have fire-resistant properties. They can be mixed with small particleboard or small fiber flakes in a general mass ratio range of 4:6 to 6:4, without any special limitation here.

[0013] The textured grooves formed on the refractory fiber layer can be custom-carved in terms of depth and shape, for example, using a commercially available fully automatic carving machine based on a pre-designed stone texture drawing. The maximum depth of the textured grooves is controlled at approximately 2.8mm, which allows them to penetrate the refractory fiber layer and reach the maximum depth of the flame-retardant adhesive layer, but it is necessary to avoid touching the core board. The natural stone texture formed in this way provides a better simulation effect compared to existing stone veneer paper technologies.

[0014] The thickness of the flame-retardant adhesive layer should be controlled between 0.1mm and 2.0mm. The flame-retardant adhesive layer is a structural layer that combines flame retardancy and adhesive properties, formed by incorporating flame retardants into organic adhesives. In this way, after the organic adhesive cures into a film, it can fully encapsulate the flame retardant, preventing direct contact between the flame retardant and moisture in the air, thus avoiding moisture absorption and corrosion.

[0015] Further optimization involves incorporating flour to enhance its adhesiveness and water retention. The organic adhesive is absorbed by the board or flows freely after application. When mixed with flour, it becomes a paste-like colloid with stronger adhesion and is less prone to water loss and curing.

[0016] Generally, the organic adhesive, flour, and flame retardant can be mixed in a mass ratio of 100:30-40:30-40, and no special restrictions are made here.

[0017] The flame-retardant adhesive layer is mainly used to bond the core board located in the core layer to the fire-resistant fiber layer located on the surface.

[0018] The real stone paint layer is a structural layer formed by using commercially available real stone paint coating materials. It can enhance the decorative effect of the fire-retardant composite decorative panel, making the natural stone texture and stone color echo each other to achieve the purpose of simulation.

[0019] Preferably, a UV layer is also provided on the stone paint layer.

[0020] The UV layer is formed by applying commercially available conventional UV coating materials. The application of the UV layer enhances the weather resistance of the flame-retardant composite decorative panel.

[0021] The present invention has achieved the following beneficial effects:

[0022] This invention combines a wood core board (i.e., core board) with a fiber cement board surface panel (refractory fiber layer), utilizing the stone properties of magnesium cementitious material and the properties of wood fiber, and by forming textured grooves on the refractory fiber layer, a simulated stone texture board with wood feel and strong flame retardant properties is obtained.

[0023] The fire-retardant composite decorative board exhibits mechanical properties far superior to common boards such as MDF and particleboard. Due to its unique structure, this wood-based board possesses moisture-proof and fire-resistant characteristics, enabling it to be used normally in most application scenarios. This is because: firstly, the core board of this fire-retardant composite decorative board retains its wood fiber structure, resulting in higher mechanical strength compared to conventional MDF and particleboard; secondly, because the fire-resistant fiber layer is a cement particleboard structure, the water absorption coefficient of cement materials is much lower than that of wood materials, exhibiting excellent moisture-proof properties.

[0024] The core board in its fire-retardant composite decorative board structure is made of solid wood splicing, which makes the overall density of the board low, and combines the heat insulation characteristics of wood board. The overall fire resistance rating of the board can reach A2 level, with excellent fire resistance performance. Attached Figure Description

[0025] Figure 1 This is a schematic diagram of the structure of the core board, flame-retardant adhesive layer and fire-resistant fiber layer (with textured grooves) of the flame-retardant composite decorative board according to Embodiment 1 of this utility model;

[0026] Figure 2 This is a structural schematic diagram of a flame-retardant composite decorative panel according to Embodiment 1 of this utility model;

[0027] Figure 3 This is a structural schematic diagram of the core board, flame-retardant adhesive layer, and fire-resistant fiber layer (with textured grooves) of the flame-retardant composite decorative board according to Embodiment 2 of this utility model;

[0028] Figure 4 This is a structural schematic diagram of a flame-retardant composite decorative panel according to Embodiment 2 of this utility model. Detailed Implementation

[0029] The following description, in conjunction with the accompanying drawings, illustrates the fire-retardant composite decorative panel with natural stone texture provided by this utility model through specific embodiments. However, those skilled in the art will understand that the following embodiments are merely specific examples of the fire-retardant composite decorative panel of this utility model and are not intended to limit its scope. Rather, these embodiments are provided to explain the specific structure and function of this utility model, thereby enabling other those skilled in the art to understand the various embodiments of this utility model and various modifications suitable for specific intended applications.

[0030] Example 1

[0031] This embodiment provides a fire-retardant composite decorative panel with a natural stone texture.

[0032] Combination Figure 1 and Figure 2 The fire-retardant composite decorative panel includes a core board 1, a flame-retardant adhesive layer 2 located on opposite sides of the core board 2, and a fire-resistant fiber layer 3 located on the outside of the flame-retardant adhesive layer 2; the outer surface of the fire-resistant fiber layer 3 has a textured groove 4, and the outer surface of the fire-resistant fiber layer 3 without the textured groove 4 and the inner wall of the textured groove 4 are also provided with a real stone paint layer 5.

[0033] As understood by those skilled in the art, each structural layer has two opposite sides. In the above structure of this embodiment, the side of each structural layer closer to the core plate 1 is the inner side, and the side farther away from the core plate 1 is the outer side.

[0034] In this embodiment, the core board 1 is a structural layer made of solid wood boards joined together with teeth along the grain and glued together with adhesive across the grain. It is made of fir wood, with a thickness of 8.8mm and a size of 1280mm*2480mm.

[0035] The flame-retardant adhesive layer 2 is a structural layer formed by mixing urea-formaldehyde resin, flour and flame retardant in a mass ratio of 100:40:40, and its thickness is 0.1mm to 0.2mm.

[0036] The refractory fiber layer 3 is made by mixing small wood shavings or small fiber sheets (20-60 mesh size) with magnesium oxysulfate cement in a mass ratio of 4:6 and hot-pressing at high temperature. The materials and processes can refer to the relevant technologies of any fiber cement board in the existing technology. The thickness of a single layer is 2.7 mm.

[0037] Several textured grooves 4, varying in depth, are provided on the outer surface of the refractory fiber layer 3, carved according to the design drawings, with a maximum depth not exceeding 2.8mm, and do not touch the core board 1. From Figure 1 and Figure 2 As can be seen, its deepest point penetrates the refractory fiber layer 3 and reaches the flame-retardant adhesive layer 2.

[0038] These textured grooves 4, compared to existing stone veneer paper, are closer to real stone in terms of texture and feel, and have a better simulation effect in highlighting the natural stone texture.

[0039] The fifth layer of the real stone paint is a structural layer formed by spraying commercially available real stone paint coating, which can significantly improve the decorative effect of the fire-retardant composite decorative panel.

[0040] Generally, the above-mentioned flame-retardant composite decorative panels can be manufactured according to the following steps: First, core board 1 and fire-resistant fiber layer 3 are made separately; then, the core board 1 and fire-resistant fiber layer 3 are bonded together using the mixed adhesive of flame-retardant adhesive layer 3 to form flame-retardant adhesive layer 3; the obtained substrate is then sent to a fully automatic engraving machine to be engraved according to the preset drawings to form texture grooves 4 on the fire-resistant fiber layer 3; finally, the obtained raw board is sent to a real stone paint coating equipment for paint spraying to form real stone paint layer 5.

[0041] Example 2

[0042] Combination Figure 3 and Figure 4 This embodiment provides another preferred flame-retardant composite decorative panel.

[0043] Its in Figure 2 Based on the structure shown, a UV layer 6 is added on the real stone paint layer 5 to increase the weather resistance of the flame-retardant composite decorative panel.

[0044] Specifically, in this embodiment, the core board 1 has a thickness of 5.8 mm and a size of 1220 mm * 2440 mm.

[0045] The flame-retardant adhesive layer 2 is formed by mixing urea-formaldehyde resin, flour, and flame retardant in a mass ratio of 100:30:30.

[0046] The refractory fiber layer 3 is formed by mixing small wood shavings or small fiber sheets with magnesium oxychloride cement at a mass ratio of 6:4 and hot pressing at high temperature. Its single layer thickness is 3.0 mm.

[0047] The textured grooves 4 formed on the refractory fiber layer 3 vary in depth, but are generally shallow in this embodiment. From Figure 3 and Figure 4 As can be seen, its deepest point is only about 0.7mm to 0.8mm, which means it is only located in the shallow part of the refractory fiber layer 3 and does not reach the flame retardant adhesive layer 2.

[0048] In this embodiment, the UV layer 6 set on the real stone paint layer 5 is obtained by spraying and curing commercially available UV coatings.

[0049] Generally, the manufacturing steps of the flame-retardant composite decorative panel provided in this embodiment are based on those in Embodiment 1. After the real stone paint layer 5 is formed, it is sent to a UV coating equipment for paint spraying and light curing to obtain the UV layer 6.

[0050] The performance of the flame-retardant composite decorative panels provided in Embodiments 1-2 of this utility model was tested, and the results are shown in Table 1 below.

[0051] Table 1 shows the performance of the flame-retardant composite decorative panels provided in Examples 1-2.

[0052]

[0053] As can be seen from Table 1 above, the fire-retardant composite decorative board provided by the embodiments of this utility model has a surface fire rating that far exceeds the requirements of the national standard GB 8624-2012, a formaldehyde emission level that far exceeds the requirements of the group standard T-CNFPIA1001-2019, and surface bonding strength and surface resistance to thermal cycling both meet the requirements of the national standard GB / T 34722-2017.

[0054] As can be seen from the surface performance tests in Table 1 above, the properties of Example 1 meet the qualified standards of the national standard GB / T 34722-2017, while the surface crack resistance and water vapor resistance of Example 2 meet the highest requirements of the national standard GB / T34722-2017, demonstrating excellent moisture resistance. This is because the UV layer has a high degree of compatibility with the surface sealing and waterproof properties of the flame-retardant composite decorative board of this utility model.

[0055] Practical use has verified that Example 2 can be applied to outdoor walls, bathrooms and other damp and extreme places, while Example 1 is more suitable for conventional indoor places.

[0056] The present invention has been described above by way of example with reference to the accompanying drawings. Obviously, the specific implementation of the present invention is not limited to the above-described manner. Any non-substantial improvements made using the inventive concept and technical solution of the present invention, or the direct application of the inventive concept and technical solution to other situations without modification, are all within the protection scope of the present invention.

Claims

1. A fire-retardant composite decorative panel with natural stone texture, characterized in that, The product includes a core board, flame-retardant adhesive layers disposed on opposite sides of the core board, and a fire-resistant fiber layer disposed on the outside of the flame-retardant adhesive layers; wherein the outer surface of the fire-resistant fiber layer has textured grooves, and the outer surface of the fire-resistant fiber layer without textured grooves and the inner wall of the textured grooves are further provided with a stone-like paint layer.

2. The flame-retardant composite decorative panel according to claim 1, characterized in that, The flame-retardant composite decorative panel also includes a UV layer disposed on the stone paint layer.

3. The flame-retardant composite decorative panel according to claim 1 or 2, characterized in that, The core board is a solid wood core board formed by gluing solid wood boards together with longitudinal and transverse grains and then pressing them together.

4. The flame-retardant composite decorative panel according to claim 3, characterized in that, The core board has a thickness of 5.8 mm, 8.8 mm or 11.8 mm, and a size of 1280 mm*2480 mm, 1220 mm*2440 mm or 1280 mm*2880 mm.

5. The flame-retardant composite decorative panel according to claim 1 or 2, characterized in that, The refractory fiber layer is a structural layer obtained by mixing wood shavings or fiber sheets with magnesium cementitious material and then hot-pressing them.

6. The flame-retardant composite decorative panel according to claim 5, characterized in that, The thickness of the refractory fiber layer is 2.6 mm to 3.0 mm.

7. The flame-retardant composite decorative panel according to claim 1 or 2, characterized in that, The flame-retardant adhesive layer is a structural layer formed by incorporating a flame retardant into an organic adhesive.

8. The flame-retardant composite decorative panel according to claim 7, characterized in that, The thickness of the flame-retardant adhesive layer is 0.1 mm to 0.2 mm.

9. The flame-retardant composite decorative panel according to claim 1 or 2, characterized in that, The maximum depth of the texture groove is 2.8 mm.

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