3D textured sheet material, manufacturing method, and applications

Abstract

The objective is to provide a sheet material having a 3D texture structure, a method for manufacturing the same, and its applications. The present invention relates to the technical field of decorative sheet materials, and more particularly to a sheet material having a 3D texture structure, a method for manufacturing the same, and its applications. The sheet material includes a base, a pattern layer, an abrasion-resistant layer, and a topcoat layer from bottom to top. The abrasion-resistant layer includes a thickness adjustment layer and a texture layer above it, and the texture layer has a base and a three-dimensional part, with the three-dimensional part located above the base. The pattern layer includes multiple connected or disconnected wood grain-shaped lines, and the three-dimensional part includes multiple connected or disconnected wood grain-shaped grooves, with at least some of the grooves corresponding to the lines in terms of position, length, or width, and the upper surface of the topcoat layer is lower than the upper surface of the three-dimensional part. The sheet material of the present invention provides excellent abrasion resistance, improved clarity of the 3D texture, and superior tactile and visual effects.

Description

[Technical Field]

[0001] This invention belongs to the technical field of decorative panel materials, and more particularly to panel materials having a 3D texture structure, a method for manufacturing the same, and its applications. [Background technology]

[0002] In the decorative paneling industry, forming pattern structures with a 3D texture effect on the substrate surface is currently achieved primarily through the following two methods.

[0003] Firstly, a convex three-dimensional effect is formed on a flat coating using a printing deposition method.

[0004] As a related existing technology, for example, CN109653465A discloses a PVC decorative board having a 3D effect and a method for manufacturing the same using 3D printing. The PVC decorative board includes a PVC board substrate, on which a UV primer layer, a UV white paint layer, a pattern layer, a UV abrasion-resistant paint layer, a textured effect layer, and a UV topcoat layer are provided in order from bottom to top. There are two UV white paint layers, three UV abrasion-resistant paint layers, and two UV topcoat layers. Among these, the textured effect layer is printed on the cured UV abrasion-resistant paint layer using a flatbed inkjet printer. This textured effect layer is a UV transparent paint, and a textured effect layer having a specific pattern is formed by depositing the paint at specific graphic positions based on the pattern of the pattern layer.

[0005] The effect formed by this deposition method is relatively hard, and the edges of the wood grain are obtuse, making it difficult to imitate the effect of real wood grain both visually and tactilely. When used as flooring, the uneven layer formed by this deposition method results in poor tactile comfort underfoot.

[0006] Secondly, a wire brush is used to remove the textured areas from the flat coating, creating a concave texture effect.

[0007] The following are some of the relevant existing technologies.

[0008] CN112739463A discloses a method and apparatus for generating a surface structure, comprising the following steps: A) applying resin A to the surface of a material; B) applying liquid B to at least a portion of resin A while resin A is in a liquid state or partially cured; C) polymerizing resin A and liquid B, respectively; D) removing the polymerized liquid B to generate a three-dimensional structure.

[0009] This patent application discloses a principle for forming textures in a concave manner and analyzes the relevant physicochemical properties of liquid B and resin A used as embossing fluid to select an appropriate liquid B. However, it does not specifically describe the performance requirements for the final product having a three-dimensional structure.

[0010] CN110773403A discloses a 3D printed sheet material having a wire brush effect on its surface. The structure of the sheet material, from bottom to top, consists of a base layer, a UV primer layer, a UV white paint layer, a UV transition paint layer, a color pattern layer, a UV abrasion-resistant paint layer, a 3D texture layer, and a UV topcoat layer. Using a flatbed inkjet printer, gloss oil is sprayed onto the uncured UV abrasion-resistant paint surface, with the position of the gloss oil corresponding to the pattern texture position of the color pattern layer. After printing is complete, the material is cured using an LED drying and curing device attached to the printer. At this time, curing is limited to the parts not covered with gloss oil, and the abrasion-resistant paint covered with gloss oil does not cure. Subsequently, a wood grain wire brush machine is used to perform a wire brush treatment on the uncured printed parts of the 3D texture layer to obtain the 3D texture layer.

[0011] This patent application describes a method of printing a gloss oil onto an uncured abrasion-resistant coating, where the gloss oil covers a portion of the coating, preventing it from hardening in a subsequent curing process, thereby creating removable grooves. Because the uncured areas of the abrasion-resistant coating covered with the gloss oil are uniform, the grooves formed by this method differ significantly from real wood grain in both visual and tactile effects. Furthermore, as shown in Figure 1 of this patent application, the surface of the formed board is flat and does not take into account the three-dimensional feel of the texture.

[0012] Generally, compared with the first method, the second method can obtain a three-dimensional texture closer to the real wood grain and has high superiority. However, the second method is still in the initial stage at present, and there are many problems to be solved. For example, using the wear-resistant layer in a semi-cured or uncured state and forming a texture layer on it with a wire brush may damage the structure of the wear-resistant layer, reduce the wear-resistant performance of the sheet material, and even damage the pattern of the pattern layer. In addition, the three-dimensional effect of the formed 3D structure is poor, the texture is not natural, and especially the sharpness is low. Summary of the Invention Problems to be Solved by the Invention

[0013] In order to solve the above-mentioned drawbacks when forming a 3D texture on a substrate, the present invention provides a sheet material having a 3D texture structure.

[0014] The sheet material having a 3D texture structure provided by the present invention improves the base for forming the 3D texture, realizes a better formation effect and visual effect of the 3D texture while ensuring the wear-resistant performance of the sheet material. Means for Solving the Problems

[0015] The present invention adopts the following solutions:

[0016] The sheet material having a 3D texture structure includes at least a substrate, a pattern layer, a wear-resistant layer, and a top coat layer from bottom to top. The wear-resistant layer includes a thickness adjustment layer and a texture layer located thereon. The texture layer includes a base portion and a three-dimensional portion, and the three-dimensional portion is located above the base portion. The pattern layer includes a plurality of connected or unconnected wood grain-shaped stripes. The three-dimensional portion includes a plurality of connected or unconnected wood grain-shaped grooves. At least a part of the grooves corresponds to the stripes in one or more points of the arrangement position, length, or width. The upper surface of at least a part of the top coat layer is lower than the upper surface of the three-dimensional portion.

[0017] Currently, most 3D digital printing plates are in the theoretical research stage, and there are relatively few 3D digital printing plates in the market. As a result of visually and tactilely comparing existing 3D digital printing plates with 2D printing plates, it was found that the 3D digital printing plates have significantly insufficient sharpness, blurred patterns, and weak tactile three-dimensionality. The inventor of the present invention analyzed these drawbacks and explored solutions.

[0018] Existing 3D digital printing plates form a three-dimensional structure on an uncured wear-resistant layer above the pattern layer. However, since the pattern layer is not protected, the pattern layer is easily damaged during wire brushing or subsequent use, resulting in low wear resistance performance. For example, in the 3D printing plate disclosed in CN110773403A mentioned in the background art, grooves are formed with a wire brush on an uncured wear-resistant layer covered with gloss oil. Whether the pattern of the pattern layer is damaged during wire brushing depends on the depth of the 3D texture. When a deeper 3D texture is required, if the depth exceeds the thickness of the wear-resistant layer, the above-mentioned problem of pattern layer damage still exists.

[0019] Also, compared with 2D printing plates, 3D printing plates need to form a 3D texture. Therefore, by forming a 3D texture on the pattern layer through a wear-resistant layer and further applying multiple topcoat layers thereon, the sharpness of the pattern of the formed plate decreases.

[0020] Therefore, how to balance the wear resistance performance and the sharpness of the pattern is an issue faced by current 3D digital printing plates.

[0021] Regarding this issue, most solutions improve the composition of the wear-resistant paint or topcoat to make the formed wear-resistant layer and topcoat layer have good wear resistance performance and transparency. Also, some solutions focus on improving the 2D ink for forming the pattern layer and strengthening the adhesion between the pattern layer and the substrate layer or primer layer.

[0022] This invention breaks with conventional methods in this field, overcomes the prejudice that adding a coating reduces pattern clarity, and creatively incorporates wear-resistant layers into the thickness adjustment layer and texture layer. The thickness adjustment layer is pre-cured and formed before the application of the texture layer, and no groove structure is formed in the thickness adjustment layer. This thickness adjustment layer protects the pattern layer from being damaged during groove formation and also provides excellent wear resistance, ensuring resistance to friction of the plate material due to external forces during use.

[0023] The texture layer of this invention is the part that forms a 3D texture structure. A groove structure is formed on it to form the three-dimensional part of the texture layer, but the groove does not penetrate the texture layer, leaving a base below the three-dimensional part, and no groove is formed on the base. After setting the wear-resistant layer on the thickness adjustment layer and the texture layer, connection strength problems inevitably arise, and in actual use, it has been found that the formed plate material is prone to peeling or falling off the surface after a period of use. By setting a base on the texture layer, a certain distance (thickness of the base) exists between the bottom of the groove and the thickness adjustment layer, and since the groove does not penetrate the thickness direction of the texture layer, the integrity of the contact surface between the thickness adjustment layer and the texture layer is ensured, and the connection strength between the two is guaranteed. In addition, if there is no base, the thickness adjustment layer is easily damaged during groove formation, and the damaged part affects the visual effect and clarity of the pattern. Therefore, compared to a wear-resistant layer without a base, the 3D texture formed in this invention has improved clarity and a superior visual effect.

[0024] Furthermore, the inventors discovered that by forming a hardened thickness adjustment layer on the pattern layer before applying the wear-resistant layer that forms the 3D texture, the thickness of the three-dimensional parts of the texture layer can be appropriately increased without affecting the sharpness of the pattern, thus maintaining ideal sharpness. By using thicker three-dimensional parts, a deeper 3D texture effect can be achieved, resulting in a noticeable unevenness even after applying the topcoat layer, bringing it closer to a natural tactile feel. For example, typically the texture layer is 100g / m². 2 At this level, the pattern becomes blurred and its clarity decreases. After forming a hardened thickness adjustment layer on the pattern layer, the texture layer portion is 150 g / m².2 Even at these levels, ideal clarity can be maintained.

[0025] The texture layer of the present invention affects the sharpness of the pattern with different thicknesses, but in this case, the sharpness can be adjusted by adjusting the coating thickness of the thickness adjustment layer.

[0026] In certain embodiments, the bottom and / or inner wall of the groove is provided with a plurality of protrusions. The protrusions may be regular or irregular, and on one side they enhance the adhesion of the topcoat and improve the surface performance of the board material, while on the other side their presence makes the tactile feel of the board material more realistic.

[0027] In certain embodiments, the number of protrusions at the bottom of at least some of the grooves exceeds the number of protrusions on the side walls, and / or the area of ​​the bottom protrusions is greater than the area of ​​the side wall protrusions.

[0028] In certain embodiments, the protrusions occupy at least 1%, or at least 5%, or at least 10%, or at least 15%, or at least 20%, or at least 25%, or at least 30%, or at least 35%, or at least 40%, or at least 45%, of the total inner surface area of ​​the groove, but typically do not exceed 50%.

[0029] In certain embodiments, the side walls and bottoms of at least some of the grooves are connected at an obtuse angle. Grooves with obtuse-angled connections have a tactile feel that closely resembles real wood grain and offer high comfort.

[0030] In certain embodiments, the side walls are provided with raised and / or recessed areas to enhance the tactile sensation.

[0031] In a particular embodiment, the depth of the groove is 0.03 mm to 0.20 mm, more preferably 0.08 mm to 0.20 mm.

[0032] In certain embodiments, at least a portion of the groove includes a central tactile enhancement portion, visual imitation portions at both ends, and a transition portion located between the tactile enhancement portion and the visual imitation portion, wherein the width of at least a portion of the visual imitation portion is smaller than the width of the tactile enhancement portion.

[0033] In a more preferred embodiment, the depth of at least some of the visually mimicking portion of the groove is smaller than the depth of the tactile-enhancing portion.

[0034] In the above technical solution, the groove is divided into three parts, each with a different primary function. The tactile enhancement section provides a more pronounced three-dimensional tactile sensation, the visual imitation section works in conjunction with the tactile enhancement section to provide a tactile sensation close to that of real wood grain, and the visual imitation section enhances the visual effect, making the board material closer to real wood grain. The transition section primarily serves to connect the two aforementioned sections. By controlling the depth and width of each section, the 3D texture effect of the board material is realized overall, bringing it closer to the texture of real wood in terms of both appearance and touch.

[0035] In certain embodiments, the thickness of the thickness adjustment layer and the thickness of the texture layer may be the same or different.

[0036] In another preferred embodiment, the thickness of the texture layer is greater than the thickness of the thickness adjustment layer. The thicknesses of both are determined based on their respective functions, with the texture layer being used to form groove structures, requiring a greater thickness to form deeper grooves and achieve a more three-dimensional 3D effect.

[0037] The abrasion-resistant layer is formed by applying an abrasion-resistant coating, the composition of which typically includes a photocurable resin, a photoinitiator, and other additives, the other additives being one or more of the following: curing agents, catalysts, crosslinking agents, smoothing agents, antioxidants, defoamers, inorganic fillers, pigments, plasticizers, etc.

[0038] In certain embodiments, the photocurable resin is one or a combination of resins such as epoxy resin, acrylic resin, acrylic-modified polyurethane resin, acrylic-modified silicone resin, and acrylic-modified epoxy resin.

[0039] In certain embodiments, the material of the thickness adjustment layer and the material of the texture layer may be the same or different.

[0040] In other embodiments, the material of the thickness adjustment layer is different from the material of the texture layer. The thickness adjustment layer and the texture layer each perform different main functions, and by selecting materials based on their respective functional requirements, the functions of different types of wear-resistant layers can be more effectively exerted.

[0041] In certain embodiments, the coating amount of the wear-resistant paint used for the thickness adjustment layer is 35 g / m 2 to 55 g / m 2 is.

[0042] In certain embodiments, the coating amount of the wear-resistant paint used for the texture layer is 150 g / m 2 or more.

[0043] In certain embodiments, the texture layer is formed by two coatings, the coating directions are opposite, the coating amount of the wear-resistant paint used for the first coating is 75 g / m 2 or more, and the coating amount of the wear-resistant paint used for the second coating is 75 g / m 2 or more.

[0044] The texture layer requires a thick thickness to form deeper grooves and emphasizes the uneven tactile sensation. The inventor of the present invention has discovered through tests that only when the total coating amount of the wear-resistant paint used for the texture layer is 150 g / m 2 or more can the formed texture achieve a tactile sensation close to that of natural wood. 150 g / m at a time 2Applying the above materials not only makes processing difficult, but the unevenness of roller application results in uneven internal structure and thickness of the texture layer, affecting the overall clarity. In this method, the texture layer is formed by two applications, and the roller application direction is reversed. This allows the second application to apply a force opposite to the internal stress of the uncured second layer, weakening or canceling out the internal stress originally present in the texture layer. This prevents cracking in the middle of the cured texture layer and overcomes the reduction in clarity caused by internal cracking.

[0045] The base material may be a sheet material with different properties, including wood and wood derivatives (e.g., SPC stone sheet). The base material is selected based on the specific application.

[0046] The thickness of the base material layer can be determined based on the specific application; for example, in the case of decorative panels for furniture, it is usually between 5 mm and 25 mm, and in the manufacture of flooring materials, it is between 2 mm and 6 mm.

[0047] In certain embodiments, the plate material further includes a white film, which is formed on the substrate in any manner, for example, by attaching a commercially available PVC white film to the substrate to adjust the base color of the substrate and improve the clarity of the printed pattern of the subsequent pattern layer.

[0048] In certain embodiments, the plate material further includes a primer layer which is applied to the white film to provide good adhesion to subsequent coatings.

[0049] In a particular embodiment, the plate material further includes a color coating layer located between the primer layer and the pattern layer.

[0050] In certain embodiments, the color coating layer is formed by applying the color coating to a cured primer with a roller or spray and allowing it to cure. The color of the color coating is determined based on the requirements of the printed pattern and is generally white, but other colors can be selected depending on the requirements of the printed pattern. This layer corrects the base color of the substrate on the one hand, adjusts the polarity of the substrate on the printed surface on the other hand, and enhances the adhesion of the pattern layer.

[0051] The primer layer, pattern layer, color coating layer, and abrasion-resistant layer can be cured by photocuring, thermal curing, or electron beam curing. Photocuring can be performed using, for example, a UV lamp, mercury lamp, LED lamp, or potassium lamp. Curing using an LED lamp, in particular, results in less light pollution.

[0052] In certain embodiments, the pattern layer is formed by printing a pattern onto a primer layer using a multi-color ink digital printer and then photocuring it. Various patterns can be printed, such as wood grain, stone, or customized patterns.

[0053] The pattern layer can be cured by photocuring, thermal curing, or electron beam curing. Photocuring can be performed using, for example, a UV lamp, mercury lamp, LED lamp, or potassium lamp. Curing using an LED lamp, in particular, results in less light pollution.

[0054] In certain embodiments, the pattern layer and texture layer are formed by digital printing, and the digital printing ink may be UV ink, weak solvent ink, water-based ink, or oil-based ink, etc.

[0055] The aforementioned topcoat layer is formed by applying a topcoat to the wear-resistant layer and curing it.

[0056] The aforementioned topcoat layer consists of one or more layers and primarily provides a glossy or matte effect to the board material, improving the glossiness of the board material surface. The topcoat layer can further impart functions to the board material such as stain resistance, mold resistance, antibacterial properties, waterproofing, fire resistance, crack resistance, anti-slip properties, negative ion emission, formaldehyde removal, and abrasion resistance.

[0057] The present invention further provides a method for manufacturing a plate material having the 3D texture structure, comprising the following steps:

[0058] S1. Apply color paint to the substrate and cure it to form a color paint layer;

[0059] S2. Print a wood grain pattern onto the color paint layer to form a pattern layer;

[0060] S3. Apply abrasion-resistant paint to the pattern layer and cure it to form a thickness adjustment layer for the abrasion-resistant layer;

[0061] S4. Apply abrasion-resistant paint to the thickness adjustment layer of the abrasion-resistant layer, and form a texture layer without curing;

[0062] S6. Apply embossing liquid to at least a portion of the surface of the texture layer;

[0063] S7. Cure the texture layer, remove any uncured or partially cured portions, and form grooves on the texture layer;

[0064] S8. A top coat is applied to the surface obtained in S7 and cured to form a top coat layer, thereby obtaining a plate material having a 3D texture structure.

[0065] In the above manufacturing method, the creative steps are steps S3 and S7.

[0066] In S3 of the present invention, when forming the wear-resistant layer, a thickness adjustment layer is first applied and then cured to form the layer. In other words, before applying the texture layer, the thickness adjustment layer is cured through a curing process.

[0067] The sheet material formed by this method has at least the following advantages:

[0068] Protection of the pattern layer: The thickness adjustment layer is cured before groove formation, and no groove structure is formed in the thickness adjustment layer. This thickness adjustment layer protects the pattern layer from being damaged during groove formation.

[0069] Excellent wear resistance: The thickness adjustment layer is a complete layer, providing excellent wear resistance and ensuring resistance to friction of the plate material due to external forces during use.

[0070] Higher clarity: This is an unexpected effect of the board material manufactured by this method. After adding an additional layer (thickness adjustment layer), the 3D texture formed by this invention has improved clarity and a superior visual effect compared to the wear-resistant layer without the thickness adjustment layer. The reason is thought to be as follows: In existing technology, the texture layer is applied directly onto the pattern layer, and the energy to cure the wear-resistant coating is usually input from above the texture layer, causing the upper wear-resistant coating to cure first and the lower wear-resistant coating to cure later. Since the wear-resistant coating undergoes a certain volume shrinkage during curing, internal stress is generated, and these internal stresses accumulate downwards, reaching their maximum value at the very bottom of the resin liquid. If the wear-resistant coating is in direct contact with the pattern layer, when the maximum internal stress exceeds the adhesive force between the pattern layer and the layer below it, slippage occurs between the pattern layer and the board surface, causing the bottom pattern layer and grooves to no longer correspond, resulting in visual blurring and a significant decrease in clarity. In this invention, a thin thickness adjustment layer is first formed on the pattern layer, resulting in weaker internal stress after curing, which does not excessively affect the pattern layer and ensures the positional accuracy of the wood grain pattern. On the other hand, in existing technologies, the texture layer is applied directly onto the pattern layer, and because the wood grain pattern on the pattern layer is discontinuous, the consistency of shrinkage during curing of the abrasion-resistant coating is affected, resulting in uneven shrinkage within the cured texture layer, causing fine marks to appear and reducing clarity. In the present invention, the surface of the thickness adjustment layer is smooth, and the abrasion-resistant coating of the texture layer shrinks consistently when curing on this surface, so no fine marks appear within the texture layer and clarity is good.

[0071] Another role of the thickness adjustment layer is to improve the clarity of the plate material by adjusting its thickness. The texture layer is the part that forms the 3D texture structure, and even if a groove structure is formed on it, it does not affect the wear resistance of the plate material. Compared to a wear-resistant layer without a thickness adjustment layer, the 3D texture formed in this invention has improved clarity and a superior visual effect.

[0072] Achieving a deeper 3D texture effect: This method allows for an appropriate increase in the thickness of the texture layer without affecting the sharpness of the pattern, maintaining ideal sharpness. By using a thicker texture layer, a deeper 3D texture effect can be achieved, resulting in a noticeable unevenness even after applying the top coat layer, bringing it closer to a natural tactile feel.

[0073] In S7 of the present invention, a base portion is left when forming grooves in the texture layer, and the formation of the base portion is based on the difference between the thickness of the texture layer and the depth of the grooves. Leaving a base portion has at least the following advantages:

[0074] Strengthening the connection between the texture layer and the thickness adjustment layer: By setting a base in the texture layer, a certain distance (base thickness) exists between the bottom of the groove and the thickness adjustment layer, and the groove does not penetrate the thickness direction of the texture layer. This ensures the integrity of the contact surface between the thickness adjustment layer and the texture layer, guaranteeing the connection strength between them.

[0075] Improved clarity: In the absence of a base, the thickness adjustment layer is easily damaged during groove formation, and the damaged areas affect the visual effect and clarity of the pattern. Therefore, compared to wear-resistant layers without a base, the 3D texture formed by the present invention has improved clarity and a superior visual effect.

[0076] The texture layer formed by the above method has a groove at the top, forming a three-dimensional part, with a base below the three-dimensional part, where no groove is formed. The three-dimensional part and the base are connected as one unit and belong to different parts of the texture layer.

[0077] In a specific embodiment, the amount of abrasion-resistant paint applied to the thickness adjustment layer is 35 g / m². 2 From 55g / m 2 That is the case.

[0078] In a particular embodiment, the amount of abrasion-resistant paint applied to the texture layer is 150 g / m². 2 That's all.

[0079] In certain embodiments, the base and three-dimensional portions of the texture layer are formed by two coats, and the amount of abrasion-resistant paint applied to the base portion is 75 g / m². 2 In summary, the amount of abrasion-resistant paint applied to the three-dimensional section is 75 g / m². 2 That's all.

[0080] In certain embodiments, the coating direction for forming the base portion and the coating direction for forming the three-dimensional portion are opposite.

[0081] In certain embodiments, in step S5, a steel brush is used to remove any uncured or partially cured portions. Using a steel brush facilitates the formation of a finer wire brush texture, and the resulting grooves have a form similar to the texture of natural wood.

[0082] The present invention employs a specific manufacturing method to form a plate material having a specific 3D texture structure, wherein the pattern exhibited by the plate material has excellent clarity, and the 3D texture exhibited has superior three-dimensionality and tactile feel.

[0083] The present invention further provides applications of the aforementioned board material or board material obtained by the aforementioned manufacturing method, specifically applications as flooring, wall panels, or ceiling panels.

[0084] In general, the present invention has the following advantages:

[0085] This invention sets the wear-resistant layer in a thickness adjustment layer and a texture layer, and does not form a groove structure in the thickness adjustment layer. This thickness adjustment layer protects the pattern layer from being damaged during groove formation and also provides excellent wear resistance, ensuring resistance to friction of the plate material due to external forces during use. The texture layer is the part that forms a 3D texture structure, and even if a groove structure is formed on it, it does not affect the wear resistance of the plate material. Compared to a wear-resistant layer without a thickness adjustment layer, the 3D texture formed in this invention has improved clarity and a superior visual effect.

[0086] 2. The thickness adjustment layer of the present invention can also be used to adjust the clarity of a plate material. By changing the thickness of the thickness adjustment layer according to the thickness of the texture layer and the depth of the grooves, the clarity of the plate material can be adjusted.

[0087] 3. By using an abrasion-resistant layer with a thickness adjustment layer, the present invention allows for an appropriate increase in the thickness of the texture layer without affecting the clarity of the pattern, thus maintaining ideal clarity. Using a thicker texture layer enables the realization of a deeper 3D texture effect, resulting in a noticeable unevenness even after applying the top coat layer, bringing it closer to a natural tactile feel.

[0088] 4. This invention utilizes grooves to increase the inter-layer connection strength and ensure the overall performance of the plate material. Explanation of the attached diagram

[0089] Figure 1 is a schematic diagram of the layer structure of the plate material provided in Example 1 of this specification;

[0090] Figure 2 is a schematic diagram of the partial three-dimensional structure of the sheet material provided in Example 1 of this specification;

[0091] Figure 3 is an enlarged schematic diagram of a partial groove in a plate material provided in Example 1 of this specification;

[0092] Figure 4 is a schematic diagram of the partial three-dimensional structure of the sheet material provided in Comparative Example 1 of this specification;

[0093] Figure 5 is a top view of the sheet material provided in Comparative Example 1 of this specification;

[0094] Figure 6 is an enlarged schematic diagram of a partial groove in a plate material provided in Comparative Example 4 of this specification. Specific implementation methods

[0095] The technical solution of the present invention will be described in detail below with reference to specific examples. [Examples]

[0096] (Example 1) As shown in Figure 1, the plate material having a 3D texture structure includes, in order from bottom to top, a base material 01, a white film 02, a primer layer 03, a color coating layer 04, a pattern layer 05, an abrasion-resistant layer 06, and a top coat layer 07.

[0097] In this example, SPC stone-plastic wood is used as the base material, with a thickness of 4 mm. A commercially available PVC white film is used as the white film, and it is attached to the base material online after the base material has been extruded.

[0098] The primer layer is formed by roller-applying a transparent acrylic clear lacquer onto the white film and curing it with a UV lamp.

[0099] The color paint layer is formed by applying white paint to the primer layer with a roller and curing it with a UV lamp.

[0100] The pattern layer is formed by printing the pattern using a multi-color ink digital printer and then light-curing it. In this embodiment, the printed pattern is a wood grain pattern, having multiple connected or disconnected wood grain-shaped lines.

[0101] The wear-resistant layer consists of two layers: a thickness adjustment layer above the pattern layer and a texture layer above the thickness adjustment layer. The thickness adjustment layer is formed by applying a transparent wear-resistant coating onto the pattern layer and then light-curing it. The curing process is completed before the application of the texture layer.

[0102] The textured layer of the wear-resistant layer is formed by applying a transparent wear-resistant coating to a thickness adjustment layer and is provided with multiple connected or disconnected wood-grain shaped grooves 06a. The width, depth, and length of the different grooves may vary, and the width, depth, and length of the grooves are related to the pattern of the pattern layer, and the grooves correspond to the lines of the pattern layer in terms of placement, length, or width, ensuring accurate pattern alignment.

[0103] The texture layer is formed by applying abrasion-resistant paint to the thickness adjustment layer, creating grooves. The maximum depth of the grooves is less than the thickness of the texture layer, the bottom portion that does not penetrate the texture layer is the base portion, and the area above the base portion is a three-dimensional part with grooves.

[0104] The topcoat layer is applied to the surface of the three-dimensional part of the wear-resistant layer, and the upper surface of the topcoat layer in the part corresponding to the groove is lower than the upper surface of the other three-dimensional parts.

[0105] Figures 2 and 3 show the results of analyzing the plate material of this embodiment using a laser contour meter.

[0106] Figure 2 shows that the surface of the plate material provided in this embodiment has a clear uneven structure due to grooves, and has a distinct uneven feel to the touch.

[0107] Figure 3 shows that some grooves have raised and recessed areas on their side walls, and irregular protrusions 06b on the bottom and side walls of the grooves. The number of protrusions at the bottom of the grooves is clearly greater than the number of protrusions on the side walls, and the area of ​​the protrusions accounts for approximately 10% of the total inner surface area of ​​the grooves. The number of protrusions can be controlled by adjusting at least the diameter and distribution density of the steel brushes on the steel rollers of the wire brush machine. For example, reducing the diameter of the steel brushes and increasing the density will reduce the number and area ratio of the protrusions.

[0108] From a single groove structure, some grooves include three parts as a whole: a central tactile enhancement section, visual imitation sections at both ends, and a transitional section located between the tactile enhancement section and the visual imitation section. The tactile enhancement section is the area with the greatest depth, reaching 0.2 mm in some grooves. In some grooves, the width of the visual imitation sections at both ends is smaller than the width of the tactile enhancement section, while in other grooves, the width of the visual imitation section at one end is smaller than the width of the tactile enhancement section, and the width of the visual imitation section at the other end is approximately equal to the width of the tactile enhancement section. Grooves with this special structure produce a wood texture that closely resembles real wood grain in terms of visual effect and tactile feel.

[0109] (Example 2) This embodiment specifically describes a method for manufacturing a plate material having a 3D texture structure according to Example 1, and includes the following steps:

[0110] (S.1) Place a white film-coated SPC plate material measuring 1260 mm in length, 970 mm in width, and 4.85 mm in thickness on the surface of a conveyor device that moves in a fixed direction;

[0111] (S.2) The SPC sheet material first passes through the first roller coating machine during conveyor processing. A photocurable primer (primer components: 90% photocurable clear lacquer HYS01-1, 5% photoinitiator 184, 0.5% photoinitiator TPO, 4.5% diluent hydroxyethyl acrylate) is applied to the surface of the coating roller of this roller coating machine, and 12 g / m² is applied during contact between the SPC sheet material and the coating roller. 2 The primer was applied to the surface of the SPC board material, and the light was emitted at 395 nm and 8 W / cm². 2 Curing with a UV lamp forms a primer layer;

[0112] (S.3) The SPC sheet material obtained in the previous step is passed through a second roller coating machine. A photocurable white paint (white paint components: 50% photocurable epoxy HYS01-1, 30% titanium dioxide, 5% photoinitiator 184, 0.5% photoinitiator TPO, 14.5% diluent hydroxyethyl acrylate) is applied to the surface of the coating roller of this roller coating machine, and 18 g / m² is applied during contact between the SPC sheet material and the coating roller. 2A white paint was applied to the primer surface, and the wavelengths were 395 nm and 8 W / cm². 2 Curing with a UV lamp yields a white color paint layer;

[0113] (S.4) The SPC board material obtained in the previous step is sent to the first inkjet printer, and the surface of the color coating layer is coated with 6-8 g / m² using the first inkjet printer. 2 The ink is sprayed and cured to form a patterned layer with a wood grain pattern on the surface of the primer layer;

[0114] (S.5) The SPC sheet material obtained in the previous step is sent to the third roller coating machine and coated with 45 g / m² onto the pattern layer surface. 2 A photocurable resin liquid (resin liquid components: 90% Dow Corning 65 Additive, 5% photoinitiator 184, 0.5% photoinitiator TPO, 4.5% diluent hydroxyethyl acrylate) was applied with a roller at 395 nm and 8 W / cm². 2 UV lamp and 160W / cm² 2 The Hg lamp is used to sequentially irradiate and cure the layer, forming a thickness adjustment layer.

[0115] (S.6) The SPC sheet material obtained in the previous step is sent to the fourth roller coating machine, and the coating rollers of the fourth roller coating machine apply 80 g / m² along the conveying direction of the SPC sheet material (the rollers themselves rotate clockwise) to the surface of the thickness adjustment layer. 2 The resin liquid (resin liquid components: 90% Dow Corning 65 Additive, 5% photoinitiator 184, 0.5% photoinitiator TPO, 4.5% diluent hydroxyethyl acrylate) is applied with a roller to form the base layer of the texture layer;

[0116] (S.7) After applying the first layer of resin liquid, the SPC sheet material is transported forward along the surface of the conveyor device, ensuring that the fourth roller applicator does not apply any force to the resin liquid before it reaches the next roller applicator;

[0117] (S.8) The SPC sheet material obtained in the previous step is sent to the fifth roller coating machine, and the coating rollers of the fifth roller coating machine apply 75 g / m² in the opposite direction to the conveying direction of the SPC sheet material (the rollers themselves rotate clockwise). 2 Apply the resin liquid (the same as the resin liquid in step (S.6)) with a roller to form the three-dimensional parts of the texture layer;

[0118] (S.9) The SPC sheet material obtained in the previous step is sent to the second inkjet printer and coated with 8 g / m² of resin on the surface. 2 The embossing solution (embossing solution components: 45.5% diacrylate monomer PEG600DA, 20.5% hydroxyphenyl methoxy HQMME, 10% 2-tert-butylhydroquinone MTBHQ, 24% diethylene glycol butyl ether) is sprayed, and the embossing solution penetrates and mixes with the resin solution;

[0119] (S.10) The SPC sheet material obtained in the previous step is treated with 395 nm and 8 W / cm 2 UV lamp and 160W / cm² 2 The material is cured deeply by sequentially irradiating it with an Hg lamp;

[0120] (S.11) The SPC sheet material obtained in the previous step is sent to a cleaning device equipped with a steel brush (steel wire diameter 0.02 mm) to remove the mixed portion of the embossing liquid and resin liquid with the brush and to form grooves in these areas;

[0121] (S.12) The SPC sheet material obtained in the previous step is passed through the 6th roller coating machine to coat it at 12 g / m². 2 Apply a top coat and use 395nm and 8W / cm². 2 The top coat layer is obtained by curing it with a UV lamp.

[0122] Comparative Example 1

[0123] The steps are basically the same as in Example 2, but in Comparative Example 1, step (S.5) was omitted, so the manufactured sheet material does not include a thickness adjustment layer. Figures 4 and 5 are schematic diagrams of the three-dimensional structure and overhead structure of the sheet material manufactured in Comparative Example 1 of this disclosure, respectively. From the figures, it can be seen that after omitting step (S.5), the average depth of the formed wood grain becomes smaller, and the texture of the sheet material surface differs significantly from real wood grain both visually and tactilely.

[0124] Comparative Example 2

[0125] The steps are basically the same as in Example 2, but in the comparative example (S.5), no curing treatment is performed after the abrasion-resistant paint is applied with a roller. The wood grain depth of the board obtained in this comparative example is the same as that of the board obtained in Example 2, but the clarity and abrasion resistance are clearly inferior.

[0126] Comparative Example 3

[0127] The steps are basically the same as in Example 2, but after step (S.8), the abrasion-resistant coating is irradiated with ultraviolet light to obtain an incompletely cured texture layer. The average depth of the formed wood grain is reduced, and its clarity decreases.

[0128] Comparative Example 4

[0129] The steps are basically the same as in Example 2, but the amount of embossing liquid applied in step (S.9) is 15 g / m². 2 The maximum depth of the formed groove slightly exceeds the thickness of the texture layer, and at the deepest point, the texture layer is penetrated. The resulting plate material has reduced clarity.

[0130] (Example 3) The steps are basically the same as in Example 2, but steps (S.6) through (S.8) are combined into a single step (S.6), as follows:

[0131] (S.6) The SPC sheet material obtained in the previous step is sent to the fourth roller coating machine, and the coating rollers of the fourth roller coating machine apply 155 g / m² to the surface of the thickness adjustment layer along the conveying direction of the SPC sheet material. 2 The resin liquid (resin liquid components: 90% Dow Corning 65 Additive, 5% photoinitiator 184, 0.5% photoinitiator TPO, 4.5% diluent hydroxyethyl acrylate) is applied with a roller to form a texture layer.

[0132] (Example 4)

[0133] The steps are basically the same as in Example 2, except that in (S.8), the roller application direction for the two coats is the same. Steps (S.6) to (S.8) of this example are as follows:

[0134] (S.6) The SPC sheet material obtained in the previous step is sent to the fourth roller coating machine, and the coating rollers of the fourth roller coating machine apply 80 g / m² along the conveying direction of the SPC sheet material (the rollers themselves rotate clockwise) to the surface of the thickness adjustment layer. 2 The resin liquid (resin liquid components: 90% Dow Corning 65 Additive, 5% photoinitiator 184, 0.5% photoinitiator TPO, 4.5% diluent hydroxyethyl acrylate) is applied with a roller to form the base layer of the texture layer;

[0135] (S.7) After applying the first layer of resin liquid, the SPC sheet material is transported forward along the surface of the conveyor device, ensuring that the fourth roller applicator does not apply any force to the resin liquid before it reaches the next roller applicator;

[0136] (S.8) The SPC sheet material obtained in the previous step is sent to the fifth roller coating machine, and the coating rollers of the fifth roller coating machine apply 75 g / m² in the direction of transport of the SPC sheet material (the rollers themselves rotate clockwise). 2 The resin liquid (the same as the resin liquid in step (S.6)) is applied with a roller to form the three-dimensional parts of the texture layer.

[0137] Product testing:

[0138] Surface abrasion resistance test: Conducted according to standard GT / T 18102-2020.

[0139] Surface scratch resistance index test: Conducted according to standard GT / T 18102-2020.

[0140] Clarity test: Conducted according to standard JIS K7374.

[0141] Tactile depth rating test.

[0142] A test to determine the degree of similarity between tactile sensation and real wood grain.

[0143] Tactile depth rating test method and criteria:

[0144] A group of 15 evaluators will be assembled to assess the tactile depth of the test material. They will touch the surface of the material with their hands, perceive the unevenness and groove depth, and record their evaluation results based on a rating scale. The rating selected by the most people will be the final rating for the material.

[0145] The depth of tactile sensation is divided into five grades, and the five grades and their evaluation criteria are shown in Table 1.

[0146] Table 1. Tactile depth grades and standards [Table 1]

[0147] Note: From Grade 1 to Grade 5, the unevenness gradually decreases, and the grooves gradually become shallower.

[0148] Test methods and criteria for the degree of similarity between tactile sensation and real wood grain:

[0149] We organized a group of 15 evaluators to conduct a test to determine the degree of tactile similarity between the wood grain and that of real wood. First, they touched the grain of real wood, then they touched the surface of the test board, evaluated the degree of similarity, recorded the evaluation results based on a grade, and the grade selected by the most people became the final evaluation grade for the board.

[0150] The degree of similarity between the tactile feel and the real wood grain is divided into four grades, and the five grades and evaluation criteria are shown in Table 2.

[0151] Table 2. Grades and standards for the degree of similarity between tactile sensation and real wood grain. [Table 2]

[0152] The performance test results for surface abrasion resistance, scratch resistance, and clarity of the plate materials for Examples 2-4 and Comparative Examples 1-4 are shown in Table 3 below:

[0153] Table 3 Performance Test Results [Table 3]

[0154] Analysis of results: Compared to Example 2, Comparative Example 1 lacks a thickness adjustment layer, resulting in a significantly reduced abrasion resistance of the resulting plate material, partial destruction of the pattern layer, and a clear decrease in clarity.

[0155] In Comparative Example 2, compared to Example 2, the texture layer is applied directly without curing the thickness adjustment layer, resulting in a clear decrease in the clarity of the formed plate structure.

[0156] Comparative Example 3 differs from Example 2 in that the embossing liquid is applied after the texture layer has not fully cured. In this case, the penetration of the embossing liquid is unfavorable, resulting in a lower depth of wood grain and a weaker three-dimensional effect of the texture. Furthermore, due to the insufficient penetration of the embossing liquid, the degree of agreement between the formed grooves and the wood grain pattern of the pattern layer decreases, resulting in reduced clarity.

[0157] Comparative Example 4 lacks a base portion for the texture layer compared to Example 2. In this structure, the clarity of the plate material is affected to a certain extent.

[0158] Compared to Example 2, Example 3 forms a textured layer in a single application. During the application process, the abrasion-resistant coating within the textured layer becomes uneven, which has a certain effect on the clarity.

[0159] Compared to Example 2, Example 4 involves applying the coating twice in the same direction to form a texture layer. This affects the sharpness compared to the application method in the opposite direction.

[0160] The test results for the tactile depth grade and the degree of similarity between the tactile feel and real wood grain of the board materials in Examples 2-4 and Comparative Examples 1-4 are shown in Table 4 below:

[0161] Table 4 Performance Test Results [Table 4]

[0162] Example 5:

[0163] The difference from Example 2 is that in step (S.11), a steel brush with a thicker steel wire (approximately 0.05 mm in diameter) is used to remove the mixed portion of the embossing liquid and resin liquid with the brush, thereby forming grooves with more protrusions on the surface in these areas. The protrusions account for approximately 30% of the total inner surface area of ​​the grooves.

[0164] Comparative Example 5:

[0165] The difference from Example 2 is that in step (S.11), a fine-bristled brush (bristle diameter approximately 0.01 mm) is used to remove the mixed portion of the embossing liquid and resin liquid with the brush, thereby forming grooves on the surface in these areas. The grooves formed by this method have almost no obvious protrusions on the surface, and the analysis by laser contour meter is shown in Figure 6.

[0166] The relevant performance test results for the board materials in Example 5 and Comparative Example 5 are shown in Table 5 below:

[0167] Table 5 Performance Test Results [Table 5]

[0168] As can be seen from Table 5, the clarity of the wood grain in Comparative Example 5 is inferior to that of the wood grain in Example 5. Furthermore, when the surfaces of the wood grains in Example 5 and Comparative Example 5 were touched, the texture of Example 5 was closer to that of real wood grain, and visually it was also closer to that of real wood grain.

Claims

1. A plate material having a 3D texture structure, comprising at least a base material, a pattern layer, an abrasion-resistant layer, and a topcoat layer from bottom to top; the abrasion-resistant layer comprising a thickness adjustment layer and a texture layer located above it, the texture layer comprising a base portion and a three-dimensional portion, the three-dimensional portion located above the base portion; the pattern layer comprising a plurality of connected or disconnected wood-grain shaped lines, the three-dimensional portion comprising a plurality of connected or disconnected wood-grain shaped grooves, at least some of the grooves corresponding to the lines in one or more points of position, length, or width, and the upper surface of at least some of the topcoat layer being lower than the upper surface of the three-dimensional portion.

2. A plate material having a 3D texture structure according to claim 1, characterized in that it has a plurality of protrusions at the bottom and / or side walls of the groove.

3. A plate material having a 3D texture structure according to claim 1, characterized in that the number of protrusions at the bottom of at least some of the grooves exceeds the number of protrusions on the side walls, and / or the area of ​​the bottom protrusions is larger than the area of ​​the side walls.

4. A plate material having a 3D texture structure according to claim 2, characterized in that the protrusions occupy at least 1% of the total inner surface area of ​​the grooves.

5. A plate material having a 3D texture structure according to claim 2, characterized in that at least some of the side walls and bottoms of the grooves are connected at an obtuse angle.

6. A plate material having a 3D texture structure according to claim 2, characterized in that the side wall has raised and / or recessed regions.

7. A plate material having a 3D texture structure according to claim 1, characterized in that the three-dimensional portion and the base portion are integrally connected.

8. A plate material having a 3D texture structure according to claim 1, characterized in that the maximum depth of the groove is less than the thickness of the texture layer.

9. A plate material having a 3D texture structure according to claim 1, characterized in that the thickness of the three-dimensional portion is greater than the thickness of the base portion.

10. A plate material having a 3D texture structure according to claim 1, characterized in that the depth of the groove is 0.03 mm to 0.20 mm.

11. A plate material having a 3D texture structure according to claim 1, characterized in that at least a portion of the grooves includes a central tactile enhancement portion, visual imitation portions at both ends, and transition portions located between the tactile enhancement portion and the visual imitation portion, and the width of at least a portion of the visual imitation portion is smaller than the width of the tactile enhancement portion.

12. A plate material having a 3D texture structure according to claim 11, characterized in that the depth of at least some of the visually mimicking portions of the grooves is smaller than the depth of the tactile-enhancing portions.

13. The amount of abrasion-resistant paint applied to the aforementioned thickness adjustment layer is 35 g / m². ２ From 55g / m ２ A plate material having a 3D texture structure according to claim 1 or 2, characterized in that it is such.

14. The amount of abrasion-resistant paint applied to the aforementioned texture layer is 150 g / m². ２ A plate material having a 3D texture structure as described in claim 1, characterized in that it is as described above.

15. The amount of abrasion-resistant paint applied to the base portion is 75 g / m². ２ The above is the amount of abrasion-resistant paint applied to the three-dimensional part, which is 75 g / m². ２ A plate material having a 3D texture structure as described in claim 14, characterized in that it is as described above.

16. The plate material having a 3D texture structure according to claim 1, characterized in that the plate material further includes a color coating layer and is located between the substrate and the pattern layer.

17. The plate material having a 3D texture structure according to claim 16, characterized in that the plate material further includes a primer layer and is located between the substrate and the color coating layer.

18. A plate material having a 3D texture structure according to claim 16 or 17, characterized in that the plate material further includes a white film located between the substrate and the primer layer.

19. A plate material having a 3D texture structure according to claim 16, characterized in that the color paint layer is white.

20. A plate material having a 3D texture structure according to claim 1, characterized in that the top coat layer comprises two or more layers.

21. Application of the board material according to any one of claims 1 to 20 to flooring, wall panels, or ceiling panels.

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