Composite floor piece and preparation method therefor

Abstract

A composite floor piece and a preparation method therefor. The composite floor piece comprises a first composite floor piece or a second composite floor piece, wherein the first composite flooring piece comprises a functional composite film, a transparent adhesive layer, a pattern layer and a base plate, which are sequentially stacked from top to bottom; the second composite floor piece comprises a color functional film, an adhesive layer and a base plate, which are sequentially stacked from top to bottom; the color functional film comprises a functional composite film and a printed film, which are arranged in a stacked manner, the printed film being in contact with the adhesive layer; and the functional composite film comprises a glaze layer, a radiation-cured layer and a polymer transparent film, which are sequentially stacked from top to bottom, the radiation-cured layer comprising an ultraviolet cured coating or a reactive polyurethane coating, the glaze layer comprising an overglaze layer or a composite glaze layer, the composite glaze layer comprising an overglaze layer and a ground glaze layer, and the ground glaze layer being in contact with the radiation-cured layer. The composite floor piece has good wear resistance and scratch resistance.

Description

Composite floor and preparation method thereof

[0001] This application claims priority to the Chinese patent application filed with the China Patent Office on September 5, 2023, with application number CN202311136289.5 and invention name “A composite floor and its preparation method”, the entire contents of which are incorporated by reference into this application. Technical Field

[0002] The invention belongs to the technical field of decorative materials, and particularly relates to a composite floor and a preparation method thereof. Background Art

[0003] PVC flooring, a lightweight flooring material, has become extremely popular in recent years, widely used in public spaces such as airports, train stations, shopping malls, hospitals, and schools, as well as in homes. Ceramic tiles are also uniquely irreplaceable as floor coverings, and their market share far exceeds that of PVC flooring. However, PVC flooring cannot meet the requirements of public spaces and high-end applications where durability is paramount. In European and American home flooring, ceramic tiles are irreplaceable in kitchens and bathrooms. However, in Chinese homes, PVC flooring is only acceptable in bedrooms and not in living rooms. This is due to the fact that the production process for PVC flooring cannot achieve the exceptionally smooth, mirror-like finish of ceramic tiles. Furthermore, PVC flooring is typically coated with only 8-20g / m² of UV coating, which provides very limited stain, abrasion, and scratch resistance, resulting in scratch-prone and short-lived stain resistance. However, ceramic tiles have been criticized for their heavy weight, high installation and transportation costs, easy breakage, difficulty in cutting, and poor foot feel. PVC flooring, on the other hand, has the advantages of being light weight, easy to cut and install, and quiet. Many manufacturers are seeking to use PVC flooring to replace ceramic tiles, but they have not found the right technology. For example, a mirror coating can be obtained on PVC flooring by spray coating or film pressing, but the curing shrinkage of the thick coating will cause the PVC flooring to warp and deform.

[0004] In recent years, lightweight inorganic boards such as calcium silicate boards, magnesium phosphate boards, and glass magnesium boards have gradually gained attention in the field of decoration. Compared with ceramic tiles, they have the advantages of being lighter and cheaper. If a mirror coating with a ceramic tile effect can be achieved on these inorganic boards, decorative materials will have achieved a leap forward. Our company’s invention patents CN202110821073.7 and CN114953666A disclose a method for preparing a mirror coating on a PVC floor to achieve a ceramic tile effect, but the process is relatively complicated and has high requirements for the coating of the final floor product manufacturer. Against this background, exploring a simpler process that can quickly and effectively achieve a mirror coating with a ceramic tile effect on different substrates has become an urgent problem to be solved in this field.

[0005] Decorative film is a new type of decorative material made from high-molecular polymers, with various additives added, and then processed through calendering and lamination. It can be combined with substrates such as wood, plastic, aluminum, iron, and inorganic boards to create a versatile decorative material. It is widely used in home appliances, audio equipment, interior decoration, and the interiors of aircraft, ships, and trains. While decorative film has seen rapid growth in recent years, due to the specific wear and scratch resistance requirements of the flooring industry, few commercially available decorative films can directly meet these requirements. The substrate must first be laminated with the decorative film before being coated with a coating to enhance its wear and scratch resistance. Mirror-finish films that meet these requirements are even more scarce.

[0006] In summary, it is of great significance to develop a composite floor with excellent wear resistance and scratch resistance and the ability to achieve the mirror effect of ceramic tiles.

[0007] Summary of the Invention

[0008] The purpose of the present invention is to provide a composite floor and a preparation method thereof. The present invention can use different substrates to prepare the composite floor and achieve a tile effect, has excellent wear resistance and scratch resistance, and has a simple application process.

[0009] In order to achieve the above object, the present invention provides the following technical solutions:

[0010] The present invention provides a composite floor, comprising a first composite floor or a second composite floor;

[0011] The first composite floor comprises a functional composite film, a transparent adhesive layer, a pattern layer and a substrate stacked in sequence from top to bottom;

[0012] The second composite floor comprises a color functional film, an adhesive layer and a substrate stacked in sequence from top to bottom; the color functional film comprises a functional composite film and a printed film stacked in sequence, and the printed film is in contact with the adhesive layer;

[0013] The functional composite film comprises a glaze layer, a radiation-cured layer and a polymer transparent film stacked in sequence from top to bottom;

[0014] The radiation-cured layer includes an ultraviolet-cured coating or a reactive polyurethane coating;

[0015] The glaze layer includes a surface glaze layer or a composite glaze layer; the composite glaze layer includes a surface glaze layer and a bottom glaze layer, and the bottom glaze layer is in contact with the radiation-cured layer.

[0016] Preferably, the material of the polymer transparent film includes one of polyvinyl chloride, polypropylene, polyester, polycarbonate, polyurethane and polymethyl methacrylate;

[0017] The thickness of the polymer transparent film is 30 to 1000 μm.

[0018] Preferably, the thickness of the radiation-cured layer is 10 to 300 μm.

[0019] Preferably, when the radiation-curable layer is a UV-curable layer, a primer layer is further provided under the radiation-curable layer;

[0020] The thickness of the primer layer is 1 to 20 μm.

[0021] Preferably, the raw materials for preparing the top glaze layer include, by weight, 5 to 50 parts of wear-resistant particles, 10 to 80 parts of multifunctional acrylic resin, 0 to 50 parts of light-curing resin, 1 to 5 parts of photoinitiator, 0 to 50 parts of reactive diluent and 0.1 to 5 parts of auxiliary agent;

[0022] The Mohs hardness of the wear-resistant particles is ≥9; the wear-resistant particles include at least one of aluminum oxide, zirconium carbide, silicon carbide, boron carbide, silicon nitride, boron nitride and diamond powder; and the particle size of the wear-resistant particles is 1 to 30 μm.

[0023] Preferably, the raw materials for preparing the surface glaze layer also include nanoparticles;

[0024] The mass percentage of the nanoparticles is 0.5 to 10%;

[0025] The nanoparticles include at least one of aluminum oxide, zirconium carbide, silicon carbide, boron carbide, silicon nitride, boron nitride and diamond; and the particle size of the nanoparticles is 20 to 300 nm.

[0026] Preferably, the thickness of the glaze layer is 3 to 20 μm.

[0027] Preferably, the raw materials for preparing the base glaze layer include, by weight, 10 to 80 parts of acrylic resin, 3 to 50 parts of low-activity acrylate monomer, 0 to 50 parts of acrylate monomer, 1 to 7 parts of photoinitiator and 0 to 20 parts of auxiliary agent;

[0028] The low-activity acrylate monomer includes at least one of hydroxyethyl methacrylate, hydroxypropyl methacrylate, glycidyl methacrylate, isobornyl methacrylate and cyclohexyl methacrylate.

[0029] Preferably, the base glaze layer has a thickness of 2 to 20 μm.

[0030] Preferably, the material of the transparent adhesive layer includes transparent UV adhesive, transparent two-component polyurethane adhesive or transparent PUR adhesive;

[0031] The material of the adhesive layer includes two-component polyurethane adhesive or PUR adhesive.

[0032] Preferably, the pattern layer comprises a printed film, a composite film of a printed film and a transparent film, or a digitally printed pattern layer;

[0033] The substrate includes a plastic substrate, a wood board, an inorganic board or a composite board;

[0034] When the substrate is a plastic substrate, the pattern layer includes a printed film, a composite film of a printed film and a transparent film, or a digitally printed pattern layer;

[0035] When the substrate is a wooden board, an inorganic board or a composite board, the pattern layer is a digitally printed pattern layer.

[0036] Preferably, the materials of the printed film and the transparent film independently include one of polyvinyl chloride, polypropylene, polyester, polycarbonate and polymethyl methacrylate.

[0037] Preferably, the thickness of the printed film in the second composite floor is 20-300 μm.

[0038] The present invention also provides a method for preparing the composite flooring according to the above technical solution. When the composite flooring is the first composite flooring, the preparation method comprises the following steps:

[0039] preparing a glaze layer on a carrier film to obtain a pre-coated film;

[0040] Coating a radiation-curable coating layer on the surface of the polymer transparent film, then applying the pre-coated film, bringing the glaze layer into contact with the radiation-curable coating layer, and performing radiation curing to obtain the functional composite film;

[0041] preparing a pattern layer on the surface of a substrate, and then laminating the pattern layer to the functional composite film using a transparent adhesive to obtain the first composite floor;

[0042] When the composite floor is the second composite floor, the preparation method includes the following steps:

[0043] preparing a glaze layer on a carrier film to obtain a pre-coated film;

[0044] After laminating the printed film and the polymer transparent film, coating the surface of the polymer transparent film with a radiation curing layer coating, and then laminating the pre-coated film, so that the glaze layer and the radiation curing layer coating come into contact, and performing radiation curing to obtain the colored functional film;

[0045] The substrate and the color functional film are bonded together using an adhesive to obtain the second composite floor.

[0046] The carrier film includes a polyester film, a polypropylene film or a polyethylene film; the thickness of the carrier film is 20 to 500 μm.

[0047] Preferably, when the glaze layer is a top glaze layer, the preparing of the glaze layer comprises: coating a top glaze layer coating on the surface of the carrier film, and performing radiation curing to obtain a pre-coated film;

[0048] When the glaze layer is a composite glaze layer, preparing the glaze layer includes:

[0049] coating a top glaze layer coating on the surface of the carrier film and performing a first radiation curing to obtain a top glaze layer;

[0050] A base glaze layer coating is applied on the surface of the top glaze layer, and a second radiation curing is performed to obtain the pre-coating film.

[0051] Preferably, when the substrate is a plastic substrate and the pattern layer is a printed film or a composite film of a printed film and a transparent film, the process of preparing the pattern layer includes: thermally bonding the pattern layer and the substrate;

[0052] When the substrate is a plastic substrate and the pattern layer is a digitally printed pattern layer, the process of preparing the pattern layer includes: directly digitally printing on the surface of the substrate;

[0053] When the substrate is a wooden board, an inorganic board or a composite board, the process of preparing the pattern layer preferably includes: directly performing digital printing on the surface of the substrate.

[0054] The present invention provides a composite flooring comprising a first composite flooring or a second composite flooring; the first composite flooring comprising a functional composite film, a transparent adhesive layer, a patterned layer, and a substrate stacked sequentially from top to bottom; the second composite flooring comprising a colored functional film, an adhesive layer, and a substrate stacked sequentially from top to bottom; the colored functional film comprising a stacked functional composite film and a printed film, the printed film being in contact with the adhesive layer; the functional composite film comprising a glaze layer, a radiation-cured layer, and a polymer transparent film stacked sequentially from top to bottom; the radiation-cured layer comprising a UV-cured coating or a reactive polyurethane coating; the glaze layer comprising a top glaze layer or a composite glaze layer; the composite glaze layer comprising a top glaze layer and a bottom glaze layer, the bottom glaze layer being in contact with the radiation-cured layer. The present invention can be used to produce composite flooring using different substrates to achieve a tile-like effect, exhibiting excellent wear and scratch resistance and a simple application process. DETAILED DESCRIPTION

[0055] The present invention provides a composite floor, comprising a first composite floor or a second composite floor;

[0056] The first composite floor comprises a functional composite film, a transparent adhesive layer, a pattern layer and a substrate stacked in sequence from top to bottom;

[0057] The first composite floor comprises a color functional film, an adhesive layer and a substrate stacked in sequence from top to bottom; the color functional film comprises a functional composite film and a printed film stacked in sequence, and the printed film is in contact with the adhesive layer;

[0058] The functional composite film comprises a glaze layer, a radiation-cured layer and a polymer transparent film stacked in sequence from top to bottom;

[0059] The radiation-cured layer includes an ultraviolet-cured coating or a reactive polyurethane coating;

[0060] The glaze layer includes a surface glaze layer or a composite glaze layer; the composite glaze layer includes a surface glaze layer and a bottom glaze layer, and the bottom glaze layer is in contact with the radiation-cured layer.

[0061] In the present invention, the substrate preferably comprises a plastic substrate, a wooden board, an inorganic board, or a composite board. In the present invention, when the substrate is a plastic substrate, the pattern layer preferably comprises a printed film, a composite film of a printed film and a transparent film, or a digitally printed pattern layer. When the substrate is a wooden board, an inorganic board, or a composite board, the pattern layer preferably comprises a digitally printed pattern layer.

[0062] In the present invention, when the pattern layer is a composite film of a printed film and a transparent film, the printed film is in contact with the substrate, and the transparent film is in contact with the transparent adhesive layer. In the present invention, the printed film is preferably made of one of polyvinyl chloride, polypropylene, polyester, polycarbonate, and polymethyl methacrylate; and the transparent film is preferably made of one of polyvinyl chloride, polypropylene, polyester, polycarbonate, and polymethyl methacrylate.

[0063] In the present invention, the thickness of the pattern layer is preferably 20 to 300 μm. In the present invention, when the pattern layer is a composite film of a printed film and a transparent film, the thickness of the printed film is preferably 30 to 150 μm, and the thickness of the transparent film is preferably 30 to 300 μm.

[0064] In the present invention, the material of the transparent adhesive layer preferably includes transparent UV adhesive, transparent two-component polyurethane adhesive, or transparent PUR adhesive. In the present invention, the thickness of the transparent adhesive layer is preferably 10 to 100 μm, more preferably 15 to 60 μm.

[0065] In the present invention, the thickness of the printed film in the second composite flooring is preferably 20 to 300 μm, more preferably 30 to 200 μm, and even more preferably 50 to 150 μm. In the present invention, the printed film is preferably printed using letterpress printing, gravure printing, offset printing, screen printing, or digital printing. In the present invention, the printed film is preferably made of one of polyvinyl chloride, polypropylene, polyester, polycarbonate, and polymethyl methacrylate.

[0066] In the present invention, the material of the adhesive layer preferably includes two-component polyurethane adhesive or PUR adhesive.

[0067] In the present invention, the material of the polymer transparent film preferably includes one of polyvinyl chloride, polypropylene, polyester, polycarbonate, polyurethane and polymethyl methacrylate. In the present invention, the thickness of the polymer transparent film is preferably 30 to 1000 μm, more preferably 100 to 800 μm, and even more preferably 150 to 500 μm.

[0068] In the present invention, the thickness of the radiation-cured layer is preferably 10 to 300 μm, more preferably 15 to 250 μm, and even more preferably 20 to 200 μm.

[0069] In the present invention, the radiation-cured layer includes an ultraviolet-cured coating or a reactive polyurethane coating.

[0070] The present invention has no particular limitation on the specific type of the UV-curable coating, and any type well known to those skilled in the art may be used.

[0071] In a specific embodiment of the present invention, the raw materials for preparing the UV-curable coating preferably include, by mass, 10 to 80 parts of a difunctional polyurethane acrylic resin, 10 to 60 parts of a multifunctional polyurethane acrylic resin, 0 to 20 parts of a reactive diluent, 0 to 5 parts of a photoinitiator and 0 to 40 parts of wear-resistant particles.

[0072] In the present invention, the weight-average molecular weight of the bifunctional polyurethane acrylic resin is preferably 1500 to 10000, the Tg is preferably -60 to 15°C, and the elongation is preferably ≥50%. In the present invention, the functionality of the multifunctional polyurethane acrylic resin is preferably >2, the weight-average molecular weight is preferably 1500 to 10000, and the Tg is preferably >50°C. In the present invention, the reactive diluent is preferably a monofunctional acrylate monomer, and the Tg of the monofunctional acrylate monomer is preferably 40 to 160°C. In the present invention, the particle size of the wear-resistant particles is preferably 10 to 300 μm, more preferably 30 to 100 μm; the wear-resistant particles preferably include at least one of silicon powder, glass powder, nepheline powder, calcined kaolin, aluminum oxide, silicon carbide powder, silicon nitride powder, boron nitride powder, and diamond powder.

[0073] In the present invention, the UV-curable layer has good toughness and low shrinkage upon curing. In the present invention, the high molecular weight main resin system combined with the high Tg monofunctional acrylate monomer can ensure that the coating has good toughness, low shrinkage and good strength after curing.

[0074] In the present invention, when the radiation-curable layer is a UV-curable layer, a primer layer is preferably provided beneath the radiation-curable layer. The thickness of the primer layer is preferably 1 to 20 μm, more preferably 3 to 15 μm. The material of the primer layer is not particularly limited; any material known to those skilled in the art can be used. In the present invention, the primer layer ensures good adhesion between the radiation-curable coating and the transparent polymer film.

[0075] The present invention has no particular limitation on the specific type of the reactive polyurethane coating, and any type well known to those skilled in the art may be used.

[0076] In a specific embodiment of the present invention, the raw materials for preparing the reactive polyurethane coating preferably include, by weight, 15-30 parts polyisocyanate, 30-70 parts polyol, 5-15 parts hydroxy acrylate, 0.5-5 parts photoinitiator, and 5-30 parts wear-resistant particles. The present invention does not specifically limit the types of the polyisocyanate, polyol, hydroxy acrylate monomer, and photoinitiator; those familiar to those skilled in the art may be used. In the present invention, the wear-resistant particles are consistent with those in the above-mentioned technical solution and will not be further described here.

[0077] In the present invention, the preparation of the reactive polyurethane coating preferably includes the following steps: chain extension of polyisocyanate and polyol to obtain a polyurethane prepolymer; local end-capping reaction of the polyurethane prepolymer with hydroxy acrylate to obtain a polyurethane characteristic structure material having isocyanate active groups and acryloyloxy groups; after adding photoinitiator and wear-resistant particles, cross-linking reaction is carried out under the action of ultraviolet light, and moisture curing cross-linking can be carried out at the same time to obtain the reactive polyurethane coating.

[0078] In the present invention, the reactive polyurethane coating contains no small molecule acrylate monomers, and only a small portion of the acryloyloxy groups react and crosslink under UV light, leaving the majority of the coating as a moisture-curing polyurethane with very low cure shrinkage. The reactive polyurethane coating exhibits both UV and moisture-curing activity, achieving a surface-free state after UV curing. Subsequent coating applications can be performed without the need for reaction and aging of the PUR components, enabling continuous production. The reactive polyurethane coating's overall components have a high molecular weight, and the crosslinking reaction forms urethane and urea bonds, providing the coating with superior wear and scratch resistance.

[0079] In the present invention, when the radiation-cured layer does not contain wear-resistant particles, the mirror effect of the composite film is improved in quality, the qualified rate of the mirror effect is greatly improved, and the tolerance to equipment, environment, and operation requirements is greatly improved. When the radiation-cured layer contains wear-resistant particles, the entire radiation-cured layer is filled with wear-resistant particles, and the wear-resistant particles aggregate to cause bulging, and the dust particle accommodation effect in the environment is weak, and a dust-free environment is required to improve the qualified rate; after using a tough mid-coat without wear-resistant particles, the radiation-cured layer is still in a liquid state when the glaze layer is transferred (described in the preparation steps below). The radiation-cured layer without wear-resistant particles not only has enough space to accommodate dust particles in the environment, but also can level the uneven parts of the surface of the polymer transparent film, the primer layer or the glaze layer.

[0080] In the present invention, the raw materials for preparing the glaze layer preferably include, by mass, 5 to 50 parts of wear-resistant particles, 10 to 80 parts of multifunctional acrylic resin, 0 to 50 parts of photocurable resin, 1 to 5 parts of photoinitiator, 0 to 50 parts of active diluent and 0.1 to 5 parts of auxiliary agent.

[0081] In the present invention, the Mohs hardness of the wear-resistant particles is preferably ≥9; the wear-resistant particles preferably include at least one of aluminum oxide, zirconium carbide, silicon carbide, boron carbide, silicon nitride, boron nitride and diamond powder; the particle size of the wear-resistant particles is preferably 1 to 30 μm, and more preferably 3 to 20 μm. In the present invention, the use of wear-resistant particles in this particle size range can ensure both good transparency and a high volume concentration of the wear-resistant particles. After the transfer process, the wear-resistant particles are concentrated on the surface of the composite film while having a mirror effect. The present invention does not specifically limit the specific types of the multifunctional acrylic resin and the photocurable resin, and those familiar to those skilled in the art can be used.

[0082] In the present invention, the raw materials used to prepare the top glaze layer preferably also include nanoparticles, with the mass percentage of the nanoparticles preferably being 0.5-10%. The nanoparticles preferably include at least one of aluminum oxide, zirconium carbide, silicon carbide, boron carbide, silicon nitride, boron nitride, and diamond. The particle size of the nanoparticles is preferably 20-300 nm. In the present invention, the combination of nanoparticles and wear-resistant particles imparts superior wear resistance to the top glaze layer. The nanoparticles can be used directly in the top glaze or after being treated with resin through processes such as dispersion and coating.

[0083] In the present invention, the thickness of the glaze layer is preferably 3 to 20 μm, more preferably 5 to 15 μm.

[0084] In the present invention, the raw materials for preparing the base glaze layer preferably include, by mass, 10 to 80 parts of acrylic resin, 3 to 50 parts of low-activity acrylate monomer, 0 to 50 parts of acrylate monomer, 1 to 7 parts of photoinitiator and 0 to 20 parts of auxiliary agent.

[0085] The present invention does not specifically limit the type of acrylic resin; any type known to those skilled in the art may be used. In the present invention, the low-reactivity acrylic ester monomer preferably includes at least one of hydroxyethyl methacrylate, hydroxypropyl methacrylate, glycidyl methacrylate, isobornyl methacrylate, and cyclohexyl methacrylate. In the present invention, the acrylic ester monomer is preferably dipropylene glycol diacrylate. In the present invention, the additives preferably include a leveling agent, a wetting agent, a defoaming agent, and an inorganic transparent powder with a particle size of less than 20 μm.

[0086] In the present invention, the thickness of the base glaze layer is preferably 2 to 20 μm, more preferably 5 to 15 μm.

[0087] In the present invention, the combination of a base glaze layer and a top glaze layer results in a composite glaze layer that can be applied independently and stored for long periods of time. After transfer, the composite glaze layer consistently maintains good adhesion to the radiation-cured layer of the radiation-cured coating. During radiation curing, the base glaze layer's surface remains partially unreacted due to oxygen inhibition. However, after transfer to the surface of the radiation-cured layer, the carrier film isolates oxygen, allowing the unreacted acrylate monomers in the composite glaze layer to cross-link with components in the radiation-cured layer during radiation curing, resulting in excellent adhesion between the coating layers. Furthermore, the base glaze layer reduces surface unevenness caused by inorganic powder in the top glaze layer, further facilitating the subsequent formation of a mirror-finish coating.

[0088] The present invention also provides a method for preparing the composite flooring according to the above technical solution. When the composite flooring is the first composite flooring, the preparation method comprises the following steps:

[0089] preparing a glaze layer on a carrier film to obtain a pre-coated film;

[0090] Coating a radiation-curable coating layer on the surface of the polymer transparent film, then applying the pre-coated film, bringing the glaze layer into contact with the radiation-curable coating layer, and performing radiation curing to obtain the functional composite film;

[0091] preparing a pattern layer on the surface of a substrate, and then laminating the pattern layer to the functional composite film using a transparent adhesive to obtain the first composite floor;

[0092] When the composite floor is the second composite floor, the preparation method includes the following steps:

[0093] preparing a glaze layer on a carrier film to obtain a pre-coated film;

[0094] After laminating the printed film and the polymer transparent film, coating the surface of the polymer transparent film with a radiation curing layer coating, and then laminating the pre-coated film, so that the glaze layer and the radiation curing layer coating come into contact, and performing radiation curing to obtain the colored functional film;

[0095] The substrate and the color functional film are bonded together using an adhesive to obtain the second composite floor.

[0096] In the present invention, unless otherwise specified, all preparation raw materials are commercially available products well known to those skilled in the art.

[0097] In the present invention, when the composite floor is a first composite floor, the preparation method includes the following steps:

[0098] preparing a glaze layer on a carrier film to obtain a pre-coated film;

[0099] Coating a radiation-curable coating layer on the surface of the polymer transparent film, then applying the pre-coated film, bringing the glaze layer into contact with the radiation-curable coating layer, and performing radiation curing to obtain the functional composite film;

[0100] A pattern layer is prepared on the surface of a substrate, and then laminated to the functional composite film using a transparent adhesive to obtain the first composite floor.

[0101] The present invention prepares a glaze layer on a carrier film to obtain a pre-coating film.

[0102] In the present invention, the carrier film preferably includes a polyester film (PET), a polypropylene film (PP) or a polyethylene film (PE); the thickness of the carrier film is preferably 20 to 500 μm, and more preferably 30 to 200 μm. Before preparing the glaze layer, the present invention also preferably includes applying a release agent on the surface of the carrier film. The present invention has no special restrictions on the type and coating amount of the release agent, and those familiar to those skilled in the art can be used. In the present invention, the release agent facilitates the subsequent peeling of the carrier film. In the present invention, by utilizing the mirror-flatness of the carrier film, the glaze layer after transfer can achieve a mirror coating with a ceramic tile effect. In addition, carrier films with different glossiness and textures can also be selected, and the glaze layer after transfer can achieve different glossiness and texture effects.

[0103] In the present invention, when the glaze layer is a top glaze layer, the preparation of the glaze layer preferably includes: coating a top glaze layer coating on the surface of the carrier film, and performing radiation curing to obtain a pre-coated film.

[0104] In the present invention, the radiation curing is preferably performed using a mercury lamp, a gallium lamp, a UV-LED lamp or a halogen lamp. The present invention has no particular limitation on the radiation curing process, and any method known to those skilled in the art can be used.

[0105] In the present invention, when the glaze layer is a composite glaze layer, the preparation of the glaze layer preferably includes:

[0106] coating a top glaze layer coating on the surface of the carrier film and performing a first radiation curing to obtain a top glaze layer;

[0107] A base glaze layer coating is applied on the surface of the top glaze layer, and a second radiation curing is performed to obtain the pre-coating film.

[0108] In the present invention, the first radiation curing and the second radiation curing are consistent with the radiation curing condition parameters defined above, which will not be repeated here.

[0109] The present invention utilizes a glaze coating transfer method on a polymer film to prepare a high-gloss mirror coating with a tile effect, thereby obtaining a high-gloss mirror functional film with excellent wear resistance and scratch resistance, thereby solving the problem that high-gloss mirror decorative films have poor wear resistance and scratch resistance and cannot be used in the ground field.

[0110] In the present invention, the side of the surface glaze layer that contacts the carrier film is isolated from oxygen during radiation curing, and is not affected by oxygen inhibition, so the performance is greatly improved. In addition, the wear-resistant particles with high hardness and high volume concentration are concentrated on one side of the carrier film. After the transfer process, it becomes a surface glaze layer with excellent wear resistance and scratch resistance. At the same time, the mirror properties of the carrier film create a mirror coating.

[0111] After obtaining the pre-coated film, the present invention applies a radiation-curing layer coating on the surface of the polymer transparent film, and then affixes the pre-coated film so that the glaze layer and the radiation-curing layer coating are in contact and radiation curing is performed to obtain the functional composite film.

[0112] In the present invention, the coating process is preferably: directly coating the radiation-curable coating layer on the surface of the polymer transparent film. In the present invention, when a primer layer is provided below the radiation-curable layer, the coating process is preferably: coating the primer layer on the surface of the polymer transparent film, curing the primer layer, and then coating the radiation-curable coating layer.

[0113] In the present invention, the coating thickness of the primer layer is preferably 1 to 20 μm, more preferably 3 to 15 μm. In the present invention, the coating thickness of the radiation-curable layer is preferably 10 to 300 μm, more preferably 20 to 200 μm.

[0114] In the present invention, the radiation curing is preferably performed using a mercury lamp, a gallium lamp, a UV-LED lamp, a halogen lamp or an EB lamp. The present invention has no particular limitation on the radiation curing process, and any method known to those skilled in the art can be used.

[0115] After the radiation curing, the present invention preferably further includes removing the carrier film and performing re-radiation curing. The present invention does not specifically limit the removal process; techniques well known to those skilled in the art may be employed. In the present invention, the re-radiation curing process is consistent with the radiation curing process defined in the above-mentioned technical solution and will not be further described here.

[0116] After obtaining the functional film, the present invention prepares a pattern layer on the surface of the substrate, and then adheres it to the functional composite film using a transparent adhesive to obtain a first composite floor.

[0117] In the present invention, when the substrate is a plastic substrate and the pattern layer is a printed film or a composite film of a printed film and a transparent film, the process of preparing the pattern layer preferably includes thermally bonding the pattern layer to the substrate. The present invention does not specifically limit the thermal bonding process; a method well known to those skilled in the art may be employed.

[0118] In the present invention, when the substrate is a plastic substrate and the pattern layer is a digitally printed pattern layer, the process of preparing the pattern layer preferably includes: performing digital printing directly on the surface of the substrate. Prior to digital printing, the present invention also preferably includes sequentially performing leveling, attaching, filling, and masking processes on the substrate. The present invention does not specifically limit the leveling, attaching, filling, and masking processes; those familiar to those skilled in the art may be employed.

[0119] In the present invention, when the substrate is a wood board, an inorganic board, or a composite board, the process of preparing the pattern layer preferably includes digital printing directly on the surface of the substrate. Prior to digital printing, the present invention also preferably includes sequentially leveling, attaching, filling, and masking the substrate. The present invention does not specifically limit the leveling, attaching, filling, and masking processes; these processes, known to those skilled in the art, may be employed.

[0120] In the present invention, when the composite floor is the second composite floor, the preparation method includes the following steps:

[0121] preparing a glaze layer on a carrier film to obtain a pre-coated film;

[0122] After laminating the printed film and the polymer transparent film, coating the surface of the polymer transparent film with a radiation curing layer coating, and then laminating the pre-coated film, so that the glaze layer and the radiation curing layer coating come into contact, and performing radiation curing to obtain a color functional film;

[0123] The substrate and the color functional film are bonded together using an adhesive to obtain the second composite floor.

[0124] The present invention prepares a glaze layer on a carrier film to obtain a pre-coating film.

[0125] In the present invention, the preparation process is consistent with the preparation method defined in the above technical solution, and will not be repeated here.

[0126] After obtaining the pre-coated film, the present invention laminates the printed film and the polymer transparent film, applies a radiation-curing layer coating on the surface of the polymer transparent film, and then laminates the pre-coated film so that the glaze layer and the radiation-curing layer coating are in contact, and radiation curing is performed to obtain a colored functional film.

[0127] The present invention does not specifically limit the process of laminating the printed film to the polymer transparent film; techniques familiar to those skilled in the art may be employed. In specific embodiments of the present invention, thermal lamination is preferred. In the present invention, the processes of coating the surface with the radiation-curable coating and curing the coating are consistent with those described in the aforementioned technical solution and are not further elaborated here.

[0128] The present invention has no particular limitation on the process of laminating the substrate and the color functional film using an adhesive, and any method known to those skilled in the art can be used. Before laminating, the present invention preferably further includes leveling the substrate.

[0129] The composite floor provided by the present invention can achieve the effect of ceramic tiles. When applied to plastic substrates, especially SPC substrates or WPC substrates, it can have the advantages of high-end mirror effect, stain resistance, wear resistance and scratch resistance of ceramic tiles and easy cutting, tongue and groove opening, easy installation and transportation, and comfortable foot feel of plastic floors. The defects of ceramic tiles being easy to break, high transportation and installation costs, and having a stiff foot feel, and the defects of plastic floors being poor in surface wear resistance and scratch resistance, and shrinkage and warping due to thick coatings are solved. When applied to inorganic boards, it can also achieve the effect of replacing ceramic tiles. Compared with ceramic tiles, it has the advantages of being lighter and cheaper.

[0130] The composite floor provided by the present invention has a simple preparation process, high selectivity for substrates, low energy consumption in the process, and is easy to realize batch production.

[0131] In order to further illustrate the present invention, a composite floor and a preparation method thereof provided by the present invention are described in detail below in conjunction with examples, but they should not be construed as limiting the scope of protection of the present invention.

[0132] Example 1

[0133] The printed film and the polymer transparent film are laminated by heat bonding. Both the printed film and the polymer transparent film are made of PVC (polyvinyl chloride). The polymer transparent film is 300 μm thick and comes from Foshan Tianan Plastic Co., Ltd. The printed film is 100 μm thick and comes from Hangzhou Lin'an Ginkgo Decorative Materials Co., Ltd.

[0134] A top glaze coating (coating thickness of 10 μm) was applied to a mirror-finished PET film with a thickness of 100 μm and cured using a mercury lamp to obtain a top glaze layer. The top glaze coating comprised 20 parts of wear-resistant particles, 37 parts of nine-functionality polyurethane acrylic resin, 20 parts of nano-hybrid resin, 2 parts of photoinitiator, 20 parts of reactive diluent, 0.4 parts of dispersant, 0.2 parts of defoamer, and 0.4 parts of anti-settling agent. The wear-resistant particles were silicon carbide micropowder with a particle size of 10 μm. The nine-functionality polyurethane acrylic resin was TUN142 from Bangfort New Materials Co., Ltd., the photoinitiator was 1173, the reactive diluent was dipropylene glycol diacrylate, and the dispersant was BASF EFKA-AFCONA- 4010, the defoaming agent is TEGO Airex 920, the anti-settling aid is fumed silica, which is Degussa R974; the nano-hybrid resin is obtained by dispersing and coating nanoparticles with a silane coupling agent using a light-curing resin; in parts by mass, the nano-hybrid resin contains 82 parts of light-curing resin, 15 parts of nanoparticles, and 3 parts of silane coupling agent. The light-curing resin is the epoxy acrylic resin TUE21 produced by Bangfort New Materials Co., Ltd., the nanoparticles are Aladdin wear-resistant alumina with a particle size of 50nm, and the silane coupling agent is Dow Corning 6011;

[0135] A base glaze coating (with a coating thickness of 7 μm) is applied to the surface of the top glaze layer and cured by a mercury lamp to obtain a pre-coated film; wherein the base glaze coating comprises 40 parts of epoxy acrylic resin, 10 parts of low-activity acrylate monomer, 30 parts of acrylate monomer, and 4 parts of photoinitiator; the epoxy acrylic resin is TUE75 produced by Bangfort New Materials Co., Ltd., the low-activity acrylate monomer is hydroxyethyl methacrylate, the acrylate monomer is dipropylene glycol diacrylate, and the photoinitiator is 1173;

[0136] After the primer layer coating is applied on the surface of the polymer transparent film (the coating thickness is 8 μm), it is cured by a mercury lamp and then coated with a radiation curing layer coating (the coating thickness is 70 μm); wherein the primer layer coating is BPVC-1335 of Bangfort New Materials Co., Ltd.; the radiation curing layer coating is MEC-04 of Bangfort New Materials Co., Ltd. (including: 55 parts of difunctional polyurethane acrylic resin, 27 parts of hexafunctional polyurethane acrylic resin, 15 parts of active diluent, 3 parts of photoinitiator. The difunctional polyurethane acrylic resin is Bangfort New Materials Co., Ltd. The six-functional polyurethane acrylic resin is TUN149 produced by Bangfute New Materials Co., Ltd., with a molecular weight of 4000, a Tg of -15°C, and an elongation of 150%; the six-functional polyurethane acrylic resin is TUN202 produced by Bangfute New Materials Co., Ltd., with a molecular weight of 3000 and a Tg of 60°C; the reactive diluent is a monofunctional acrylate monomer, including 5 parts of hydroxyethyl methacrylate and 10 parts of 4-acryloylmorpholine, the Tg of hydroxyethyl methacrylate is 55°C, and the Tg of 4-acryloylmorpholine is 145°C; the photoinitiator includes 0.5 parts of TPO and 2.5 parts of 184);

[0137] The obtained pre-coated film is applied on the radiation-cured layer coating, and after radiation curing with a gallium lamp, the carrier film is immediately removed, and then radiation curing is performed again with a mercury lamp to obtain a colored functional film;

[0138] The obtained colored functional film was applied to the leveled SPC substrate using a PUR adhesive to prepare a second composite floor.

[0139] Example 2

[0140] The printed film and the polymer transparent film are laminated by heat bonding. Both the printed film and the polymer transparent film are made of PVC (polyvinyl chloride). The polymer transparent film is 300 μm thick and comes from Foshan Tianan Plastic Co., Ltd. The printed film is 100 μm thick and comes from Hangzhou Lin'an Ginkgo Decorative Materials Co., Ltd.

[0141] A top glaze coating (coating thickness of 15 μm) is applied on a mirror PET film with a thickness of 100 μm, and cured by a mercury lamp to obtain a top glaze layer; wherein the top glaze coating comprises: 40 parts of wear-resistant particles, 20 parts of nine-functionality polyurethane acrylic resin, 15 parts of light-curing resin, 2 parts of photoinitiator, 22 parts of active diluent, 0.4 parts of dispersant, 0.2 parts of defoaming agent, and 0.4 parts of anti-settling aid; the wear-resistant particles comprise 5 parts of diamond micropowder, 10 parts of silicon carbide micropowder and 25 parts of aluminum oxide, and the particle size of each is 10 μm; ... The functional polyurethane acrylic resin is TUN142 from Bonfort New Materials Co., Ltd., the light-curing resin is epoxy acrylic resin TUE75 from Bonfort New Materials Co., Ltd., the photoinitiator is 1173, the reactive diluents include 10 parts of pentaerythritol triacrylate and 12 parts of dipropylene glycol diacrylate, the dispersant is BASF EFKA-AFCONA-4010, the defoamer is TEGO Airex 920, and the anti-settling aid is fumed silica, Degussa R974.

[0142] A base glaze coating (with a coating thickness of 5 μm) is applied to the surface of the top glaze layer and cured by a mercury lamp to obtain a pre-coated film; wherein the base glaze coating comprises 40 parts of epoxy acrylic resin, 10 parts of low-activity acrylate monomer, 30 parts of acrylate monomer, and 4 parts of photoinitiator; the epoxy acrylic resin is TUE75 produced by Bangfort New Materials Co., Ltd., the low-activity acrylate monomer is hydroxyethyl methacrylate, the acrylate monomer is dipropylene glycol diacrylate, and the photoinitiator is 1173;

[0143] After the primer layer coating is applied on the surface of the polymer transparent film (the coating thickness is 8 μm), it is cured by a mercury lamp and then coated with a radiation curing layer coating (the coating thickness is 70 μm); wherein the primer layer coating is BPVC-1335 of Bangfort New Materials Co., Ltd.; the radiation curing layer coating is MEC-04 of Bangfort New Materials Co., Ltd. (including: 55 parts of difunctional polyurethane acrylic resin, 27 parts of hexafunctional polyurethane acrylic resin, 15 parts of active diluent, 3 parts of photoinitiator. The difunctional polyurethane acrylic resin is Bangfort New Materials Co., Ltd. The six-functional polyurethane acrylic resin is TUN149 produced by Bangfute New Materials Co., Ltd., with a molecular weight of 4000, a Tg of -15°C, and an elongation of 150%; the six-functional polyurethane acrylic resin is TUN202 produced by Bangfute New Materials Co., Ltd., with a molecular weight of 3000 and a Tg of 60°C; the reactive diluent is a monofunctional acrylate monomer, including 5 parts of hydroxyethyl methacrylate and 10 parts of 4-acryloylmorpholine, the Tg of hydroxyethyl methacrylate is 55°C, and the Tg of 4-acryloylmorpholine is 145°C; the photoinitiator includes 0.5 parts of TPO and 2.5 parts of 184);

[0144] The obtained pre-coated film is applied on the radiation-cured layer coating, and after radiation curing with a gallium lamp, the carrier film is immediately removed, and then radiation curing is performed again with a mercury lamp to obtain a colored functional film;

[0145] The obtained colored functional film was applied to the leveled SPC substrate using a PUR adhesive to prepare a second composite floor.

[0146] Example 3

[0147] The colored functional film prepared in the manner of Example 1;

[0148] The obtained colored functional film is applied to the leveled calcium silicate board using a PUR adhesive to prepare a second composite floor.

[0149] Example 4

[0150] The colored functional film prepared in the manner of Example 1;

[0151] The obtained colored functional film is applied to the leveled glass magnesium board using a two-component polyurethane adhesive to prepare a second composite floor.

[0152] Example 5

[0153] The printed film and polymer transparent film were attached by thermal bonding. The polymer transparent film was made of polyethylene terephthalate-1,4-cyclohexanedimethanol (PETG), with a thickness of 500 μm, and was sourced from Anhui Aokai Materials Co., Ltd. The printed film was made of PVC, with a thickness of 50 μm, and was sourced from Hangzhou Lin'an Ginkgo Decorative Materials Co., Ltd.

[0154] The pre-coated film was prepared in the manner of Example 1;

[0155] A radiation-curable coating layer (coating thickness of 30 μm) is coated on the surface of the polymer transparent film; wherein the radiation-curable coating layer is a reactive polyurethane coating having both UV curing activity and moisture curing activity, and is ST-UN258 produced by Bangfort New Materials Co., Ltd.;

[0156] The obtained pre-coated film is applied on the radiation-cured layer coating, and after radiation curing with a gallium lamp, the carrier film is immediately removed, and then radiation curing is performed again with a mercury lamp to obtain a colored functional film;

[0157] The obtained colored functional film was applied to the leveled SPC substrate using a PUR adhesive to prepare a second composite floor.

[0158] Example 6

[0159] A radiation-cured layer and a glaze layer were prepared on the surface of a polymer transparent film in the manner of Example 1 to obtain a functional composite film. The polymer transparent film was made of polyvinyl chloride (PVC) with a thickness of 400 μm and was obtained from Foshan Tianan Plastic Co., Ltd.

[0160] After thermal bonding of the PVC substrate and the printed film (pattern layer), the obtained functional composite film was applied to the printed film using transparent UV adhesive to prepare the first composite floor; the printed film was made of PVC with a thickness of 70 μm and was sourced from Hangzhou Lin'an Ginkgo Decorative Materials Co., Ltd.

[0161] Example 7

[0162] Prepare according to the structure of the first composite floor:

[0163] The polymer transparent film is made of polyester (PET) with a thickness of 200 μm and is from Anhui Aokai Materials Co., Ltd.

[0164] A pre-coating film was prepared in the manner of Example 1;

[0165] Coating a radiation-curing layer coating (coating thickness of 30 μm) on the surface of the polymer transparent film; wherein the radiation-curing layer coating is ST-UN258 produced by Bangfute New Materials Co., Ltd.;

[0166] The obtained pre-coated film is applied on the radiation-cured layer coating, and after radiation curing with a gallium lamp, the carrier film is immediately removed, and then radiation curing is performed again with a mercury lamp to obtain the functional composite film;

[0167] After thermal bonding of the PVC substrate and the printed film (pattern layer), the obtained functional composite film was applied to the printed film using transparent UV adhesive to prepare the first composite floor. The printed film was made of PVC with a thickness of 70 μm and was sourced from Hangzhou Lin'an Ginkgo Decorative Materials Co., Ltd.

[0168] Example 8

[0169] Prepare according to the structure of the first composite floor:

[0170] The polymer transparent film is made of polyester (PET) with a thickness of 500 μm and is from Anhui Aokai Materials Co., Ltd.

[0171] A pre-coated film was prepared in the same manner as in Example 1, except that a matte PET film with a thickness of 70 μm was used as the carrier film;

[0172] After the primer layer coating is applied on the surface of the polymer transparent film (the coating thickness is 8 μm), it is cured by a mercury lamp and then coated with a radiation curing layer coating (the coating thickness is 70 μm); wherein the primer layer coating is BPVC-1335 of Bangfort New Materials Co., Ltd.; the radiation curing layer coating is MEC-04 of Bangfort New Materials Co., Ltd. (including: 55 parts of difunctional polyurethane acrylic resin, 27 parts of hexafunctional polyurethane acrylic resin, 15 parts of active diluent, 3 parts of photoinitiator. The difunctional polyurethane acrylic resin is Bangfort New Materials Co., Ltd. The six-functional polyurethane acrylic resin is TUN149 produced by Bangfute New Materials Co., Ltd., with a molecular weight of 4000, a Tg of -15°C, and an elongation of 150%; the six-functional polyurethane acrylic resin is TUN202 produced by Bangfute New Materials Co., Ltd., with a molecular weight of 3000 and a Tg of 60°C; the reactive diluent is a monofunctional acrylate monomer, including 5 parts of hydroxyethyl methacrylate and 10 parts of 4-acryloylmorpholine, the Tg of hydroxyethyl methacrylate is 55°C, and the Tg of 4-acryloylmorpholine is 145°C; the photoinitiator includes 0.5 parts of TPO and 2.5 parts of 184);

[0173] The obtained pre-coated film is applied on the radiation-cured layer coating, and after radiation curing with a gallium lamp, the carrier film is immediately removed, and then radiation curing is performed again with a mercury lamp to obtain the functional composite film;

[0174] The inorganic fiberboard is leveled, attached, filled, and masked, and then digitally printed to obtain a pattern layer. The obtained functional composite film is then applied to the pattern layer of the inorganic fiberboard using a transparent UV adhesive to prepare a first composite floor.

[0175] Example 9

[0176] A transparent composite film was prepared in the same manner as in Example 8;

[0177] The PVC substrate is leveled, attached, filled, and masked, and then digitally printed to obtain a pattern layer. The obtained functional composite film is then applied to the pattern layer of the PVC substrate using a transparent UV adhesive to prepare a first composite floor.

[0178] Example 10

[0179] The printed film and the polymer transparent film were laminated in the same manner as in Example 1;

[0180] The pre-coated film was prepared in the manner of Example 1;

[0181] After a primer layer coating is applied on the surface of the polymer transparent film (with a coating thickness of 8 μm), it is cured by a mercury lamp and then coated with a radiation curing layer coating (with a coating thickness of 120 μm); wherein the primer layer coating is BPVC-1335 produced by Bangfort New Materials Co., Ltd.; the radiation curing layer coating comprises: 42 parts of a difunctional polyurethane acrylic resin, 20 parts of a hexafunctional polyurethane acrylic resin, 15 parts of a reactive diluent, 3 parts of a photoinitiator, and 20 parts of wear-resistant particles; the difunctional polyurethane acrylic resin is TUN149 produced by Bangfort New Materials Co., Ltd. , molecular weight of 4000, Tg of -15℃, elongation of 150%; hexafunctional polyurethane acrylic resin is TUN202 of Bangfute New Materials Co., Ltd., with a molecular weight of 3000 and Tg of 60℃; the reactive diluent is a monofunctional acrylate monomer, including 5 parts of hydroxyethyl methacrylate and 10 parts of 4-acryloylmorpholine, hydroxyethyl methacrylate Tg of 55℃, 4-acryloylmorpholine Tg of 145℃; the photoinitiator includes 0.5 parts of TPO and 2.5 parts of 184; the wear-resistant particles are aluminum oxide with a particle size of 50μm;

[0182] The obtained pre-coated film is applied on the radiation-cured layer coating, and after radiation curing with a gallium lamp, the carrier film is immediately removed, and then radiation curing is performed again with a mercury lamp to obtain the colored functional film;

[0183] The obtained colored functional film was adhered to the SPC substrate using a PUR adhesive to prepare a second composite floor.

[0184] Example 11

[0185] The printed film and the polymer transparent film were laminated in the same manner as in Example 1;

[0186] A top glaze coating (coating thickness of 5 μm) was applied on a mirror PET film with a thickness of 50 μm, and a mercury lamp was used for curing to obtain a pre-coated film; wherein, the top glaze coating included: 20 parts of wear-resistant particles, 37 parts of nine-functionality polyurethane acrylic resin, 20 parts of nano-hybrid resin, 2 parts of photoinitiator, 20 parts of active diluent, 0.4 parts of dispersant, 0.2 parts of defoaming agent, and 0.4 parts of anti-settling aid; the wear-resistant particles were silicon carbide micropowder with a particle size of 10 μm; the nine-functionality polyurethane acrylic resin was TUN142 produced by Bangfort New Materials Co., Ltd., the photoinitiator was 1173, the active diluent was dipropylene glycol diacrylate, and the particle size was 10 μm. The powder is BASF EFKA-AFCONA-4010, the defoaming agent is TEGO Airex 920, and the anti-settling agent is fumed silica, namely Degussa R974. The nano-hybrid resin is obtained by dispersing and coating nanoparticles with a silane coupling agent using a light-curing resin. In parts by mass, the nano-hybrid resin contains 82 parts of light-curing resin, 15 parts of nanoparticles, and 3 parts of silane coupling agent. The light-curing resin is the epoxy acrylic resin TUE21 produced by Bangfort New Materials Co., Ltd., the nanoparticles are Aladdin wear-resistant alumina with a particle size of 50 nm, and the silane coupling agent is Dow Corning 6011.

[0187] After the primer layer coating is applied on the surface of the polymer transparent film (the coating thickness is 8 μm), it is cured by a mercury lamp and then coated with a radiation curing layer coating (the coating thickness is 70 μm); wherein the primer layer coating is BPVC-1335 of Bangfort New Materials Co., Ltd.; the radiation curing layer coating is MEC-04 of Bangfort New Materials Co., Ltd. (including: 55 parts of difunctional polyurethane acrylic resin, 27 parts of hexafunctional polyurethane acrylic resin, 15 parts of active diluent, 3 parts of photoinitiator. The difunctional polyurethane acrylic resin is Bangfort New Materials Co., Ltd. The six-functional polyurethane acrylic resin is TUN149 produced by Bangfute New Materials Co., Ltd., with a molecular weight of 4000, a Tg of -15°C, and an elongation of 150%; the six-functional polyurethane acrylic resin is TUN202 produced by Bangfute New Materials Co., Ltd., with a molecular weight of 3000 and a Tg of 60°C; the reactive diluent is a monofunctional acrylate monomer, including 5 parts of hydroxyethyl methacrylate and 10 parts of 4-acryloylmorpholine, the Tg of hydroxyethyl methacrylate is 55°C, and the Tg of 4-acryloylmorpholine is 145°C; the photoinitiator includes 0.5 parts of TPO and 2.5 parts of 184);

[0188] The obtained pre-coated film is applied on the radiation-cured layer coating, and after radiation curing with a gallium lamp, the carrier film is immediately removed, and then radiation curing is performed again with a mercury lamp to obtain the colored functional film;

[0189] The obtained colored functional film was adhered to the SPC substrate using a PUR adhesive to prepare a second composite floor.

[0190] Performance Testing

[0191] (1) Scratch resistance

[0192] The scratch resistance of the composite flooring, SPC flooring, and ceramic tiles obtained in Examples 1 to 11 was tested according to GB / T 9279.1-2015. The needle diameter was 0.5 mm. The higher the test data, the better the scratch resistance.

[0193] (2) Impact resistance

[0194] The impact resistance of the composite flooring, SPC flooring, and ceramic tile obtained in Examples 1 to 11 was tested with reference to GB / T 17657-2013.

[0195] (3) Wear resistance

[0196] With reference to GB / T 1768-2006, the wear resistance of the composite flooring, SPC flooring, and ceramic tile obtained in Examples 1 to 11 was tested. The test conditions were: 500 g load, P180 sandpaper, and 100 revolutions of the test abrasion value. The smaller the abrasion value, the better the wear resistance.

[0197] (4) Repetitive traffic scratches

[0198] According to the additional test method HSP1305MM of EN 16094-2021, the composite flooring, SPC flooring, and ceramic tiles obtained in Examples 1 to 11 were tested for their resistance to repeated traffic scratches, and the evaluation grades were C1 to C5 from good to poor.

[0199] (5)Pollution resistance

[0200] The stain resistance of the composite flooring, SPC flooring, and ceramic tile obtained in Examples 1 to 11 was tested with reference to GB / T 17657-2013. The test pollutants were coffee, 25% sodium hydroxide, and iodine tincture. The evaluation level was 5 to 1 from good to bad.

[0201] The test results are shown in Table 1;

[0202] Table 1 Performance test results of the composite flooring obtained in Examples 1 to 11

[0203] As can be seen from Table 1, the composite floor prepared using the composite film provided by the present invention can achieve a mirror-like ceramic tile surface effect, and has both the elasticity of the plastic floor (excellent impact resistance) and the excellent wear resistance, scratch resistance, and pollution resistance of the ceramic tile.

[0204] Although the above embodiment provides a detailed description of the present invention, it is only a part of the embodiments of the present invention, not all of the embodiments. Other embodiments can be obtained based on this embodiment without creativity, and these embodiments all fall within the scope of protection of the present invention.

Claims

1. A composite floor, characterized in that: comprising a first composite floor or a second composite floor; The first composite floor comprises a functional composite film, a transparent adhesive layer, a pattern layer and a substrate which are stacked in sequence from top to bottom; The second composite floor comprises a color functional film, an adhesive layer and a substrate stacked in sequence from top to bottom; the color functional film comprises a functional composite film and a printed film stacked in sequence, and the printed film is in contact with the adhesive layer; The functional composite film comprises a glaze layer, a radiation-cured layer and a polymer transparent film stacked in sequence from top to bottom; The radiation-cured layer includes an ultraviolet-cured coating or a reactive polyurethane coating; The glaze layer includes a surface glaze layer or a composite glaze layer; the composite glaze layer includes a surface glaze layer and a bottom glaze layer, and the bottom glaze layer is in contact with the radiation-cured layer.

2. The composite floor according to claim 1, characterized in that: The material of the polymer transparent film includes one of polyvinyl chloride, polypropylene, polyester, polycarbonate, polyurethane and polymethyl methacrylate; The thickness of the polymer transparent film is 30 to 1000 μm.

3. The composite floor according to claim 1, characterized in that: The thickness of the radiation-cured layer is 10 to 300 μm.

4. The composite floor according to claim 1 or 3, characterized in that: When the radiation-cured layer is an ultraviolet light-cured layer, a primer layer is further provided under the radiation-cured layer; The thickness of the primer layer is 1 to 20 μm.

5. The composite flooring according to claim 1, characterized in that: The raw materials for preparing the surface glaze layer include, by weight, 5 to 50 parts of wear-resistant particles, 10 to 80 parts of multifunctional acrylic resin, 0 to 50 parts of photocurable resin, 1 to 5 parts of photoinitiator, 0 to 50 parts of active diluent and 0.1 to 5 parts of auxiliary agent; The Mohs hardness of the wear-resistant particles is ≥9; the wear-resistant particles include at least one of aluminum oxide, zirconium carbide, silicon carbide, boron carbide, silicon nitride, boron nitride and diamond powder; the particle size of the wear-resistant particles is 1 to 30 μm.

6. The composite flooring according to claim 5, characterized in that: The raw materials for preparing the surface glaze layer also include nanoparticles; The mass percentage of the nanoparticles in the glaze layer is 0.5-10%; The nanoparticles include at least one of aluminum oxide, zirconium carbide, silicon carbide, boron carbide, silicon nitride, boron nitride and diamond; and the particle size of the nanoparticles is 20-300 nm.

7. The composite floor according to claim 1, 5 or 6, characterized in that: The thickness of the glaze layer is 3-20 μm.

8. The composite flooring according to claim 1, characterized in that: The raw materials for preparing the base glaze layer include, by weight, 10 to 80 parts of acrylic resin, 3 to 50 parts of low-activity acrylate monomers, 0 to 50 parts of acrylate monomers, 1 to 7 parts of photoinitiators and 0 to 20 parts of auxiliary agents; The low-activity acrylic acid ester monomer includes at least one of hydroxyethyl methacrylate, hydroxypropyl methacrylate, glycidyl methacrylate, isobornyl methacrylate and cyclohexyl methacrylate.

9. The composite floor according to claim 1 or 8, characterized in that: The thickness of the base glaze layer is 2-20 μm.

10. The composite flooring according to claim 1, characterized in that: The material of the transparent adhesive layer includes transparent UV adhesive, transparent two-component polyurethane adhesive or transparent PUR adhesive; The material of the adhesive layer includes two-component polyurethane adhesive or PUR adhesive.

11. The composite flooring according to claim 1, characterized in that: The substrate includes a plastic substrate, a wooden board, an inorganic board or a composite board; When the substrate is a plastic substrate, the pattern layer includes a printed film, a composite film of a printed film and a transparent film, or a digitally printed pattern layer; When the substrate is a wooden board, an inorganic board or a composite board, the pattern layer is a digitally printed pattern layer.

12. The composite flooring according to claim 1, characterized in that: The materials of the printed film and the transparent film independently include one of polyvinyl chloride, polypropylene, polyester, polycarbonate and polymethyl methacrylate.

13. The composite flooring according to claim 1, characterized in that: The thickness of the printed film in the second composite flooring is 20 to 300 μm.

14. The method for preparing the composite floor according to any one of claims 1 to 13, characterized in that: When the composite floor is a first composite floor, the preparation method comprises the following steps: preparing a glaze layer on a carrier film to obtain a pre-coated film; The radiation curing layer coating is applied on the surface of the polymer transparent film, and then the pre-coated film is applied. The glaze layer is brought into contact with the radiation-cured layer coating, and radiation-cured is performed to obtain the functional composite film; Preparing a pattern layer on the surface of a substrate, and then bonding it to the functional composite film using a transparent adhesive to obtain the first composite floor; When the composite floor is the second composite floor, the preparation method comprises the following steps: preparing a glaze layer on a carrier film to obtain a pre-coated film; After laminating the printed film and the polymer transparent film, coating the surface of the polymer transparent film with a radiation curing layer coating, and then laminating the pre-coated film, so that the glaze layer and the radiation curing layer coating are in contact, and radiation curing is performed to obtain the color functional film; The substrate and the color functional film are bonded together using an adhesive to obtain the second composite floor.

15. The preparation method according to claim 14, characterized in that: The carrier film includes a polyester film, a polypropylene film or a polyethylene film; the thickness of the carrier film is 20 to 500 μm.

16. The preparation method according to claim 14, characterized in that: When the glaze layer is a surface glaze layer, the preparation of the glaze layer comprises: coating a surface glaze layer coating on the surface of the carrier film, and performing radiation curing to obtain a pre-coated film; When the glaze layer is a composite glaze layer, preparing the glaze layer comprises: Coating a surface glaze coating on the surface of the carrier film and performing a first radiation curing to obtain a surface glaze layer; A base glaze layer coating is applied on the surface of the top glaze layer, and a second radiation curing is performed to obtain the pre-coating film.

17. The preparation method according to claim 14, characterized in that: When the substrate is a plastic substrate and the pattern layer is a printed film or a composite film of a printed film and a transparent film, the process of preparing the pattern layer includes: thermally bonding the pattern layer and the substrate; When the substrate is a plastic substrate and the pattern layer is a digitally printed pattern layer, the process of preparing the pattern layer includes: directly performing digital printing on the surface of the substrate; When the substrate is a wooden board, an inorganic board or a composite board, the process of preparing the pattern layer preferably includes: directly performing digital printing on the surface of the substrate.

Images