Non-polyvinyl-chloride wood-plastic board having three-dimensional wood grain, and preparation method therefor and use thereof

Abstract

The present invention relates to the technical field of flooring manufacturing, and specifically relates to a non-polyvinyl-chloride wood-plastic board having three-dimensional wood grain, and a preparation method therefor and the use thereof. The non-polyvinyl-chloride wood-plastic board comprises a non-polyvinyl-chloride wood-plastic substrate layer containing a polyolefin resin having a surface energy that is not higher than 35 dynes / cm, and an attachment bottom that is adhered to one side of the non-polyvinyl-chloride wood-plastic substrate layer and has a surface tension smaller than that of the polyolefin resin. The non-polyvinyl-chloride wood-plastic board further comprises a two-dimensional pattern layer, a three-dimensional wear-resistant layer and a finishing paint layer. In the present invention, by defining the surface energy relationship between the attachment bottom and the non-polyvinyl-chloride wood-plastic substrate layer, the phenomenon of peeling, warping and cracking of the non-polyvinyl-chloride wood-plastic board can be effectively prevented, thereby effectively improving the stability and durability of the board. Moreover, the prepared non-polyvinyl-chloride wood-plastic board can achieve environmentally friendly production and recycling of the wood-plastic board, and the visual sensation and the tactile sensation of the wood-plastic board are closer to those of three-dimensional wood grain of real wood grain.

Description

Non-polyvinyl chloride wood-plastic board with three-dimensional wood grain and preparation method and application thereof TECHNICAL FIELD

[0001] The present application relates to the technical field of floor manufacturing, in particular to a non-polyvinyl chloride wood-plastic board with three-dimensional wood grain and a preparation method and application thereof. BACKGROUND

[0002] As an important part of the building material industry, the floor industry has witnessed the continuous evolution and transformation of various types of floors as people's pursuit of quality of life continues to grow. From traditional solid wood floors to modern composite floors, to today's new three-dimensional floors, the floor industry has witnessed the continuous evolution and transformation of various types of floors. Looking forward to the future, with the increasing demand for building decoration and the accelerated urbanization process, the floor industry has a promising future.

[0003] Among them, three-dimensional floor is a uniquely designed floor that uses visual effects and material combinations to give it a three-dimensional and depth. This type of floor usually creates a three-dimensional visual effect through the clever combination of different materials, colors and textures, as well as unique pattern designs, giving people a more spacious and rich spatial experience.

[0004] Currently, with the increasing demand for interior decoration and design, there is an increasing demand for personalized, fashionable and artistic decorative materials. As a decorative material with unique visual effects and artistic sense, three-dimensional floor is becoming increasingly popular with more and more consumers. At the same time, with the rapid development of technology, the manufacturing process of three-dimensional floor will continue to improve, and material selection and design innovation will further enhance the market competitiveness of three-dimensional floor. It can be predicted that three-dimensional floor will continue to be concerned and favored in the market in the future.

[0005] Polyvinyl chloride (PVC) material has a wide range of applications in three-dimensional floor due to its good durability, excellent water resistance and easy cleaning and maintenance.

[0006] For example, the patent with the authorization announcement number CN112095967B discloses a multi-layer synchronous register embossed round edge PVC panel, which includes a UV paint layer, a PVC wear-resistant layer, a PVC pattern film layer, a PVC base plate and a PVC bottom material layer. The panel surface has a synchronous register simulation three-dimensional texture, and the four corners have a circular arc edge and a lock structure, realizing the mutual lock and splice of the panels.

[0007] In addition, the patent with the publication number CN114953665A discloses a preparation process of PVC floor, which stacks a PVC base plate layer, a PVC printing layer and a PVC pre-coating film, and performs one-time lamination treatment to obtain a PVC floor product.

[0008] However, as PVC flooring is widely used, its inherent defects gradually emerge:

[0009] Firstly, although PVC materials have strong stability and durability, they also pose difficulties in recycling. Meanwhile, due to the need for special treatment methods during the recycling process, the recycled materials may not be reused, which reduces the resource recovery rate of PVC artificial flooring and causes resource waste.

[0010] Secondly, during production, use, and disposal, PVC artificial flooring may release harmful substances such as volatile organic compounds (VOCs). These volatile organic compounds pose potential risks to the environment and human health, particularly in indoor environments, which may lead to decreased air quality and potentially trigger allergic reactions or respiratory diseases.

[0011] In addition, due to the poor heat resistance of PVC materials, long-term exposure to high-temperature environments may cause softening deformation or even release of harmful gases. This limits the application of PVC artificial flooring in certain special environments, such as near stoves or in places exposed to sunlight.

[0012] Finally, the production process of PVC artificial flooring may generate a large amount of harmful waste gas and wastewater, causing negative impacts on the environment. Its characteristics of being not conducive to sustainable development have gradually attracted people's attention, promoting the development and application of green and environmentally friendly materials.

[0013] Therefore, technicians are seeking alternative materials to address these issues, including wood-plastic flooring made of polyolefin materials (such as polypropylene, polyethylene, etc.) or polyester materials (such as PET, PETG, PBT, etc.) as candidate solutions. These new materials have better environmental friendliness and durability, and are expected to become the development trend of the flooring industry in the future.

[0014] For example, the patent with publication number CN117511148A provides a NON-PVC plastic floor and its manufacturing process, which uses PET-P, PET-G, or PP resin, calcium powder, various lubricants, processing aids, etc. to mix and synthesize, then granulates through a specially designed extruder, and then uses an extruder for secondary extrusion processing to produce NONPVC-LVT floor and NONPVC-SPC floor products. The LVT floor and SPC floor manufactured by replacing the originally considered toxic PVC with PET-P, PET-G, or PP resin have better comprehensive physical indicators, performance, and service life than the replaced products.

[0015] In addition, the patent with publication number CN109944411A discloses a PET plastic floor, which at least includes a substrate layer and a printing layer arranged on the substrate layer. The substrate layer is made of PET or a mixture of PET and PE material or a mixture of PET and PP material. The printing layer is formed by spraying patterns on the substrate layer in a digital spraying manner or by adhering the printing layer to the upper surface of the substrate layer. A protective layer is further arranged on the printing layer. The PET plastic floor does not contain halogen and will not produce dioxin when burning, which helps to reduce air pollution. The invention can use new PET or recycled PET, and then combine with PE, PP and other high molecular thermoplastic materials to form the substrate layer. Then, according to the required properties, the printing layer and wear-resistant layer are compounded on the substrate layer to form an environmentally friendly and recyclable plastic floor. The PET plastic floor can be recycled to form renewable resources for recycling.

[0016] However, the applicant of the present application found that when using polyolefin materials to prepare three-dimensional floor, the adhesion between the substrate and the three-dimensional surface layer is weak, which easily leads to delamination, warping and cracking problems. This situation has not been observed in traditional PVC substrates. The applicant has tried to use the adhesion materials used in PVC substrates to enhance the adhesion between the polyolefin substrate and the three-dimensional layer, but the result is not satisfactory.

[0017] Therefore, based on the above-mentioned defects, the non-polyvinyl chloride wood-plastic board prepared by using polyolefin materials encounters certain obstacles in the production of three-dimensional floor. In order to overcome these problems, a series of targeted optimization and improvement of the three-dimensional floor prepared by using polyolefin materials and its preparation process are needed to improve the quality, stability and environmental protection of the non-polyvinyl chloride wood-plastic board. Through innovation and technological progress, more choices are brought to the floor industry, and the whole industry is promoted to a more sustainable and environmentally friendly direction.

[0018] SUMMARY

[0019] The present application is to overcome the defects in the prior art that the adhesion between the substrate and the three-dimensional layer of the non-polyvinyl chloride wood-plastic board is weak, which leads to low stability of the non-polyvinyl chloride wood-plastic board. Therefore, a new type of non-polyvinyl chloride wood-plastic board with three-dimensional wood grain and its preparation method and application are provided to overcome the above-mentioned deficiencies.

[0020] To achieve the above-mentioned application purposes, the present application is realized by the following technical solutions:

[0021] In a first aspect, the present application first provides a non-polyvinyl chloride wood-plastic board with three-dimensional wood grain, which comprises:

[0022] a non-polyvinyl chloride wood-plastic substrate layer, which comprises a polyolefin resin with a surface energy not higher than 35 mN / m;

[0023] an adhesive primer on one side of the non-polyvinyl chloride wood-plastic substrate layer; wherein,

[0024] the surface tension of the adhesive primer is less than the surface tension of the polyolefin-based resin, and the difference between the surface tension of the adhesive primer and the surface tension of the polyolefin-based resin is less than 5 mN / m;

[0025] a two-dimensional pattern layer attached to the adhesive primer away from the non-polyvinyl chloride wood-plastic substrate layer; wherein,

[0026] the two-dimensional pattern layer comprises a plurality of connected or unconnected two-dimensional wood grain lines obtained by digital printing;

[0027] a three-dimensional wear-resistant layer above the two-dimensional pattern layer, the three-dimensional wear-resistant layer comprising a three-dimensional base layer covering the entire two-dimensional pattern layer and a three-dimensional wear-resistant layer comprising at least a portion or all of the protrusions or grooves corresponding to the two-dimensional wood grain lines or the gaps between the two-dimensional wood grain lines in the two-dimensional pattern layer;

[0028] a surface paint layer on the surface of the three-dimensional wear-resistant layer, at least a portion of the surface paint layer being lower than the upper surface of the three-dimensional wear-resistant layer.

[0029] The present application uses a non-polyvinyl chloride wood-plastic board as a substrate layer, combines digital printing technology and three-dimensional layer design, and realizes the environmentally friendly production and recycling of wood-plastic boards. This structural design not only reduces the consumption of traditional wood, promotes resource conservation and recycling, but also meets the requirements of modern society for environmental protection and sustainable development, and has good social benefits and market prospects.

[0030] Specifically, the non-polyvinyl chloride wood-plastic board with three-dimensional wood grain in the present application is endowed with a unique three-dimensional wood grain appearance through the wood grain lines obtained by digital printing in the two-dimensional pattern layer and the design of the three-dimensional base layer and the protrusions / grooves of the three-dimensional wear-resistant layer, so as to create a simulated wood texture and improve the visual effect and artistic sense of the product.

[0031] In order to enhance the bonding stability between the substrate and the adhesive layer, methods such as corona treatment are usually used to increase the surface energy of the substrate, thereby enhancing the bonding strength between the substrate and other layer structures. However, the present inventors have found that after the substrate is treated by means such as corona treatment, the surface energy of the substrate will indeed increase for a period of time, but this effect will decrease over time, so that the improvement of the bonding strength by using such technical means can only be maintained for a short period of time. In addition, if the surface energy of the substrate is excessively increased by means such as corona treatment, the bonding stability between the substrate and the adhesive primer may even decrease. Therefore, the existing technology is difficult to achieve long-term and stable improvement of the bonding stability between the substrate and the adhesive primer.

[0032] For the flooring industry, the design service life of the floor is usually several years or even decades, and it is often subjected to external mechanical impact (such as the movement of pedestrians, the falling and accumulation of heavy objects, etc.) and environmental climate tests (such as light, cold and heat, wind and rain, bacteria, etc.) during the design service life. Due to the multi-layer structure of the three-dimensional floor, the above tests will cause irreversible damage (such as delamination, cracking, warping, etc.) to the three-dimensional floor with a multi-layer structure. In addition, these challenges are even more severe for three-dimensional floors suitable for outdoor use. Therefore, some existing ways to improve the bonding stability between the substrate and the attached bottom often cannot be used for a long time.

[0033] Furthermore, the non-polyvinyl chloride wood-plastic panel with three-dimensional wood grain described in the present application as a new type of floor material represents a new trend in the development of the flooring industry, replacing traditional polyvinyl chloride wood-plastic panels. However, the current industry still has limited research on non-polyvinyl chloride wood-plastic panels themselves, and their physical and chemical properties are not yet clear. Therefore, the method for improving the long-term bonding stability between the polyolefin-based resin and the attached bottom is still unclear, and it is necessary for researchers in the industry to continue to invest a lot of effort in further research.

[0034] The inventors of the present application found in the experimental process that although the surface energy of the substrate is an important parameter for characterizing the adhesion ability of the material surface, it has an important influence on the stability of the three-dimensional wood-plastic panel, but the inventors also found that there is a more significant relationship between the surface energy relationship between the two materials and the bonding strength between them.

[0035] Based on this discovery, the present application achieves the stability and reliability of the panel under use and environmental changes by controlling the surface energy difference between the non-polyvinyl chloride wood-plastic substrate layer and the attached bottom to be less than 5 mN / m in the design.

[0036] The reason is that an appropriate surface energy difference range can help balance the surface energy of the two materials, so that the non-polyvinyl chloride wood-plastic substrate layer and the attached bottom are better combined, maintaining a relatively stable state, which helps to prevent deformation and damage of the panel under different temperature and humidity environments. The inventors of the present application found in experiments that when the surface energy difference between the polyvinyl chloride wood-plastic substrate layer and the attached bottom is within the set range, the two are more firmly combined, effectively preventing peeling and improving the stability and durability of the panel.

[0037] As a preferred, the polyolefin-based resin is any one or a combination of polyethylene, polypropylene, polyisobutylene, ethylene-vinyl acetate copolymer, ethylene-polypropylene copolymer, ethylene-acrylic acid or acrylic ester copolymer, and poly-4-methyl-1-pentene.

[0038] As preferred, the adhesion of the non-polyvinyl chloride wood-plastic substrate layer to the adhesive bottom is rated 5B according to the method described in ASTM D3359.

[0039] As preferred, the non-polyvinyl chloride wood-plastic substrate layer further comprises fillers and processing aids.

[0040] As preferred, the fillers are wood powder and / or stone powder.

[0041] As preferred, the adhesive bottom is obtained by curing a photocurable resin composition;

[0042] The photocurable resin composition comprises a main resin with photosensitive groups attached;

[0043] The main resin further comprises both hydrogen bond donor groups and hydrogen bond acceptor groups for forming hydrogen bonds.

[0044] The adhesive bottom in the present application is cured from a photocurable resin composition, which comprises a main resin with photosensitive groups, hydrogen bond donor groups and hydrogen bond acceptor groups for forming hydrogen bonds. The photosensitive groups have high sensitivity to light and can quickly respond to the irradiation of light sources, making the photocurable resin have the characteristics of rapid curing, forming a strong adhesive bottom, shortening the production cycle, and improving the production efficiency and throughput.

[0045] Moreover, due to the presence of hydrogen bond donor and acceptor groups in the photocurable resin composition, the interaction force between the main resin and the substrate layer can be enhanced through hydrogen bond formation. This unique structure forms stronger chemical bond during the curing process, improving the bonding strength and adhesion between the adhesive bottom and the substrate layer, ensuring the stability and durability of the wood-plastic panel structure.

[0046] In addition, the present application utilizes the combination of hydrogen bond donor and acceptor groups to make the adhesive bottom formed by the photocurable resin composition have more uniform and stable surface treatment quality. The formation of hydrogen bonds helps to reduce the tension of the material surface, reduce the unevenness of surface energy, enhance the consistency and flatness of surface treatment, and improve the processing stability and quality control ability in the panel production process.

[0047] Finally, the photocuring technology itself belongs to a green and environmentally friendly curing method, without the need to add solvents or other harmful substances, avoiding the emission of volatile organic compounds, meeting the requirements of environmental protection and sustainable development. This design realizes the green and environmentally friendly production process by curing the adhesive bottom with photocurable resin, and provides a sustainable solution for the material selection and production of wood-plastic panels.

[0048] As preferred, the photocurable resin composition has a dynamic viscosity of 80 seconds-250 seconds.

[0049] The light-cured resin composition has a dynamic viscosity ranging from 80 seconds to 250 seconds, which can meet the bonding and curing requirements within a proper time. The moderate dynamic viscosity allows the resin to have proper viscosity and fluidity during the coating and coating process, ensuring uniform coating and complete coverage, and facilitating the firm bonding between the adhesive primer and the substrate layer and the curing effect. At the same time, the proper dynamic viscosity improves the operability and stability of the production process, making the resin more easily controllable and operable during the coating and curing process. The resin has moderate viscosity and viscosity, which can effectively adhere to the substrate surface without being too fluid or diluted, maintaining the stability and continuity of the production process and improving the efficiency and quality of product production.

[0050] As a preferred, the adhesive primer has a weight of 10 g / m 2 - 15 g / m 2 .

[0051] In actual tests, the inventors found that the coating amount of the adhesive primer has a significant impact on the bonding strength of the substrate and the deformation control of the wood-plastic panel. When the coating amount of the adhesive primer is less than 10 g / m 2 , it is found that the bonding strength between the adhesive primer and the non-polyvinyl chloride wood-plastic substrate layer is low, which may cause problems such as delamination and cracking of the three-dimensional floor; and when the coating amount of the adhesive primer exceeds 15 g / m 2 , the shrinkage of the adhesive primer during curing is too large, which may cause the three-dimensional floor to warp.

[0052] As a preferred, the main resin contains any one of amide group, imide group, amino group, carbamate group, hydroxyl group, and urea group.

[0053] As a preferred, the light-cured resin composition further contains an auxiliary resin having a photosensitive group and an active diluent.

[0054] At least one of the auxiliary resin and the active diluent contains a hydrogen bond acceptor group.

[0055] The present application can improve the photosensitivity and reaction speed of the light-cured resin composition by adding an auxiliary resin containing a photosensitive group and an active diluent, especially a component containing a hydrogen bond acceptor group. Under light conditions, the photosensitive group absorbs light energy to promote the light curing reaction of the resin, and the active ingredient containing the hydrogen bond acceptor group accelerates the curing process and promotes the photoinitiated polymerization reaction, thereby improving the curing efficiency and shortening the curing time.

[0056] The hydrogen bond acceptor groups in the added auxiliary resin and active diluent improve the selectivity and controllability of the curing reaction of the photocuring resin composition. The hydrogen bond acceptor groups participate in the hydrogen bond interaction in the curing process, help to regulate the curing reaction speed and mechanism, improve the selectivity of the curing reaction, and make the curing process more controllable and stable. By precisely controlling the hydrogen bond interaction, adjusting the molecular structure and crosslinking degree of the photocuring resin, the hardness, wear resistance and chemical corrosion resistance of the product are improved, and the durability and stability are enhanced.

[0057] In addition, the auxiliary resin and active diluent containing hydrogen bond acceptor groups can also enhance the adhesion and weather resistance between materials. The hydrogen bond acceptor groups help to form a tighter bond with the surrounding matrix material, improve the adhesion of the cured resin to the substrate, and enhance the water resistance, temperature resistance and chemical corrosion resistance of the product, prolonging the service life of the product.

[0058] In summary, the present application introduces auxiliary resin and active diluent containing photosensitive groups, which contain at least one hydrogen bond acceptor group, which helps to improve the photocuring efficiency, improve the selectivity and controllability of the curing reaction, optimize the physical properties and durability, improve the surface quality and appearance of the product, and enhance the adhesion and weather resistance of the material, bringing more advantages and protection to the performance and application of the photocuring resin composition.

[0059] As a preferred, the addition amount of the main resin is 30wt%-40wt% of the total mass of the photocuring resin composition; and the addition amount of the auxiliary resin is not higher than 50wt% of the addition amount of the main resin.

[0060] The addition amount of the active diluent is not higher than 65wt% of the addition amount of the main resin.

[0061] The present application specifically limits the addition amount of the main resin, auxiliary resin and active diluent in the photocuring resin composition to ensure that the finally produced wood-plastic board has better anti-cracking and delamination effect.

[0062] The addition amount of the main resin is controlled between 30wt% and 40wt% of the total mass of the photocuring resin composition, which can ensure that the photocuring resin composition has enough curing main body to maintain chemical stability and curing effect. The main resin is a key component of the photocuring reaction, and appropriate control of the addition amount helps to maintain the balance and stability of the curing reaction, ensuring that the product has excellent physical and chemical properties after curing.

[0063] The addition amount of the auxiliary resin should not exceed 50wt% of the main resin, so as to adjust the formation of network structure and optimize the curing speed. The appropriate amount of auxiliary resin can support and stabilize the network structure during the curing process, promote the curing reaction, and avoid excessive addition leading to network structure disorder and excessive curing speed affecting the curing effect.

[0064] The addition amount of the active diluent should not exceed 65wt% of the main resin, which helps to control the balance between the curing volume and the coating performance. The appropriate amount of active diluent can adjust the curing volume and coating performance, improve the uniformity and curing efficiency of coating, and maintain the surface quality and consistency of the product.

[0065] Therefore, by reasonably setting the addition ratio of the main resin, auxiliary resin and active diluent, the process performance and stability of the photocuring resin composition can be optimized. The appropriate ratio can maintain the balance and coordination of the composition, improve the controllability and stability of the production process, and ensure that the product quality and performance meet the requirements.

[0066] As a preferred, the addition amount of the auxiliary resin is not less than 25wt% of the main resin.

[0067] In this application, the addition amount of the auxiliary resin is set to be not less than 25wt% of the main resin, which can enhance the flexibility and toughness of the photocuring resin composition, and effectively adjust the balance between the curing volume and surface hardness. The appropriate amount of auxiliary resin helps to optimize the curing speed and degree of photocuring resin, avoids the over-hard or over-soft curing system, and maintains the hardness and uniformity of the product surface. In addition, the appropriate amount of auxiliary resin can improve the flowability and ductility of the resin system during the curing process, so that the cured product has better elasticity and tensile resistance, and improves the wear resistance and impact resistance of the product.

[0068] At the same time, the appropriate amount of auxiliary resin can also improve the transparency and optical performance of the resin system. The composition of the auxiliary resin can optimize the refractive index and transparency of the cured layer, so that the light can penetrate the resin system more smoothly, improve the transparency and optical effect of the product, and make the wood grain more clear and visible when digital wood grain printing is performed on the surface.

[0069] As a preferred, the addition amount of the active diluent is not less than 40wt% of the main resin.

[0070] And the addition amount of the active diluent is set to be no less than 40wt% of the addition amount of the main resin, which can effectively adjust the viscosity and fluidity of the photocuring resin composition. The appropriate amount of active diluent helps to reduce the viscosity of the resin system, making it more flowable, improving the uniformity of coating and curing efficiency, while helping to avoid the phenomenon of bubbles or uneven coating, ensuring the surface quality of the product. In addition, the appropriate amount of active diluent can also speed up the curing speed of the resin system, shorten the curing time, improve the production efficiency, while ensuring the curing degree and quality of the product. Finally, the active diluent also helps to reduce the surface tension of the photocuring resin composition, reduce the generation of coating marks and defects, make the product surface more smooth and smooth, improve the gloss and transparency, thereby enhancing the surface gloss and transparency of the product.

[0071] As preferred, the photocuring resin composition further comprises a photoinitiator, a filler and an auxiliary agent.

[0072] As preferred, the addition amount of the photoinitiator is 3wt%-5wt% of the total mass of the photocuring resin composition;

[0073] The addition amount of the filler is 20wt%-30wt% of the total mass of the photocuring resin composition;

[0074] The addition amount of the auxiliary agent is 0.5wt%-1wt% of the total mass of the photocuring resin composition.

[0075] As preferred, the photoinitiator is a free radical photoinitiator.

[0076] As preferred, the active diluent contains at least two branched chains containing acrylic acid structure.

[0077] The branched chain containing acrylic acid structure in the active diluent of the present application can enhance the cross-linking property of the molecular chain of the active diluent. The presence of multiple acrylic acid structure chains can promote the formation of more cross-linking bonds between the active diluent molecules, thereby increasing the connection points of the molecular chain, and further improving the stability and durability of the molecular chain, which helps to improve the structural strength and anti-aging ability of the active diluent.

[0078] In addition, the polarity of the acrylic acid structure chain helps the compatibility of the active diluent with the resin matrix, which is conducive to the uniform dispersion of the active diluent in the resin system, enhances the stability and uniformity of the resin system, and improves the quality and performance of the product. At the same time, the softness and plasticity of the acrylic acid structure chain make the active diluent and the main resin form a closer combination, promote the interaction and chemical reaction between the two, reduce the interfacial tension, improve the interfacial bonding strength, make the resin more easily penetrate and cover the surface of the substrate, enhance the adhesion and adhesion, and ensure the firmness and durability of the cured layer.

[0079] As a preferred, the active diluent is any one of tripropylene glycol diacrylate (TPGDA), trimethylolpropane triacrylate (TMPTA), pentaerythritol triacrylate (PETA).

[0080] As a preferred, the filler is any one or a combination of more than one of silicon dioxide, calcium carbonate, aluminum oxide, titanium dioxide, magnesium oxide, talc powder, wollastonite powder, mica powder, precipitated barium sulfate, bentonite, calcium carbonate powder, ultra-fine aluminum silicate.

[0081] As a preferred, the adhesive base contains a color hiding agent for hiding the color of the non-polyvinyl chloride wood-plastic substrate layer; the two-dimensional pattern layer is printed on the surface of the adhesive base.

[0082] As another preferred, the surface of the adhesive base away from the non-polyvinyl chloride wood-plastic substrate layer is further covered with a color hiding film for hiding the color of the non-polyvinyl chloride wood-plastic substrate layer;

[0083] The two-dimensional pattern layer is printed on the surface of the color hiding film.

[0084] As another preferred, the surface of the adhesive base away from the non-polyvinyl chloride wood-plastic substrate layer is further covered with a color paint layer containing a color hiding agent;

[0085] The two-dimensional pattern layer is printed on the surface of the color paint layer.

[0086] In the present application, by adding a color hiding agent in the adhesive base or covering a color hiding film or color paint layer on the surface of the adhesive base away from the non-polyvinyl chloride wood-plastic substrate layer, the color of the non-polyvinyl chloride wood-plastic substrate itself can be hidden, providing more possibilities for subsequent customized design. At the same time, the clarity and protection of the pattern printed in the two-dimensional pattern layer can be enhanced, thereby helping the pattern printing to be more fine and clear, and prolonging the durability of the pattern.

[0087] In the present application, the printing of the two-dimensional pattern layer can realize the customization of the pattern, so that the wood-plastic board has a personalized appearance, meeting the different customer needs and design requirements. Through the cooperation of the color hiding agent, the color hiding film, the color paint layer and the surface printing of the two-dimensional pattern, the matching and coordinated overall effect between the layers of the product can be realized. The unity or contrast of color, pattern and texture makes the overall appearance of the wood-plastic board more layered and harmonious, improving the overall quality and visual effect of the product.

[0088] In a second aspect, the present application further provides a method for preparing the non-polyvinyl chloride wood-plastic board with three-dimensional wood grain as described above, comprising the following steps:

[0089] providing a non-polyvinyl chloride wood-plastic substrate layer;

[0090] - coating a layer of photocuring resin composition on the surface of the non-polyvinyl chloride wood-plastic substrate layer, and curing the photocuring resin composition to obtain the adhesion primer, so that the difference in surface energy between the adhesion primer and the non-polyvinyl chloride wood-plastic substrate layer is less than 5 mN / m;

[0091] - printing on the surface of the adhesion primer to obtain a two-dimensional pattern layer;

[0092] - three-dimensional printing on the surface of the two-dimensional pattern layer to obtain a three-dimensional wear-resistant layer;

[0093] - coating a topcoat on the surface of the three-dimensional wear-resistant layer and curing to obtain the topcoat layer.

[0094] Preferably, the photocuring resin composition has a dynamic viscosity of 80 seconds to 250 seconds.

[0095] The photocuring resin composition has an application amount of 10 g / m 2 - 15 g / m 2 .

[0096] Preferably, the two-dimensional pattern layer is directly printed on the surface of the adhesion primer.

[0097] Preferably, the photocuring resin composition further comprises a color hiding agent for hiding the color of the non-polyvinyl chloride wood-plastic substrate layer.

[0098] Preferably, before printing the two-dimensional pattern layer, a step of coating a color paint layer on the surface of the adhesion primer and curing the color paint layer is further included, and the two-dimensional pattern layer is directly printed on the surface of the color paint layer.

[0099] Preferably, the color paint layer is white.

[0100] Preferably, the color paint is cured by photocuring.

[0101] The color paint at least comprises a photocrosslinking resin, a photoinitiator, and a white pigment powder.

[0102] Preferably, the color paint has a coverage of 15 g / m 2 - 20 g / m 2 .

[0103] Preferably, before printing the two-dimensional pattern layer, a step of hot-bonding a color hiding film for hiding the color of the non-polyvinyl chloride wood-plastic substrate layer on the surface of the adhesion primer is further included, and the two-dimensional pattern layer is directly printed on the surface of the color hiding film.

[0104] Preferably, the preparation steps of the three-dimensional wear-resistant layer comprise:

[0105] - a step of covering at least a part of the surface of the two-dimensional pattern layer with a resin liquid, and curing the resin liquid to form a three-dimensional base layer;

[0106] - a step of covering at least a part of the surface of the three-dimensional base layer with at least one layer of resin liquid;

[0107] - a step of applying embossing liquid to at least a part of the surface of the resin liquid on the surface of the three-dimensional base layer along the wood grain pattern of the two-dimensional pattern layer, so that the embossing liquid and / or at least a part of the resin liquid mixed with the embossing liquid and / or at least a part of the resin liquid covered by the embossing liquid forms an embossed layer;

[0108] - a step of curing the resin liquid except for the embossed layer formed in the previous step;

[0109] - a step of removing the embossed layer, thereby forming a three-dimensional wear-resistant layer on the surface of the three-dimensional base layer.

[0110] As a preference, the amount of resin liquid used to form the three-dimensional base layer is 30g / m 2 - 50g / m 2 .

[0111] As a preference, the amount of resin liquid covering the surface of the three-dimensional base layer is greater than or equal to 150g / m 2 , and at least a part of the surface of the three-dimensional base layer is covered with at least two layers of resin liquid.

[0112] Applicants have found in practical exploration that, in order to make the wood grain on the three-dimensional wear-resistant layer of the board surface closer to the feel of natural wood, it is necessary to control the coating amount of the resin liquid used to form the three-dimensional wood grain. After testing, it is found that only when the total amount of resin liquid used for the three-dimensional base layer and the three-dimensional wood grain layer is greater than 200g / m 2 , can the texture formed thereby achieve a feel close to natural wood, while providing better wear resistance. However, when the resin liquid is coated at one time in an amount greater than 200g / m 2 , it is difficult to instantaneously cure the bottom of the wear-resistant layer, resulting in poor bonding force between the three-dimensional wear-resistant layer and the two-dimensional pattern layer on the board surface, and easy peeling between the three-dimensional wear-resistant layer and the substrate.

[0113] In order to achieve smooth curing of the resin liquid with large coating amount and improve the bonding force between the three-dimensional wear-resistant layer and the substrate, it is necessary to increase the curing power used during curing. However, the provision of large power will generate more waste heat during the curing process, which will cause deformation of the board and yellowing or aging of the resin liquid, so this means of increasing the curing power is not practical.

[0114] After the applicant studies the solidified three-dimensional wear-resistant layer, it is found that the three-dimensional wear-resistant layer actually comprises two functional zones in the longitudinal direction, including: (1) a bonding zone for bonding with the non-polyvinyl chloride base material, i.e., the three-dimensional base layer in the present application; and (2) a functional zone for forming a three-dimensional structure, i.e., the three-dimensional wear-resistant layer in the present application. Among them, the three-dimensional base layer does not require a large amount of resin, while the amount of the three-dimensional wear-resistant layer needs to be 150g / m 2 Only in this way can the approximate natural wood feel and better wear resistance be achieved.

[0115] Therefore, the present application coats the surface of the two-dimensional pattern layer with a first layer of resin liquid, and solidifies to obtain a three-dimensional base layer. Since the amount of resin liquid used to form the three-dimensional base layer is not large, it can be completely solidified under normal curing power, so that the bonding force between the three-dimensional base layer and the non-polyvinyl chloride wood-plastic base material layer containing the adhesive bottom can be effectively improved, and the peeling problem during use can be avoided. Subsequently, resin coating is performed on the surface of the three-dimensional base layer, and the resin coating amount is ensured to be 150g / m 2 The above is used to form a three-dimensional wear-resistant layer, thereby ensuring the three-dimensional effect of the three-dimensional wood grain.

[0116] As a preferred, in the process of covering the surface of the three-dimensional base layer with any two adjacent layers of resin liquid, a transition treatment step of stopping applying force to the resin liquid after the three-dimensional base layer is covered with any one layer of resin liquid is further included, and the covering of the next layer of resin liquid is performed after the transition treatment step is completed.

[0117] As described above, in the present application, in order to ensure the three-dimensional effect of the three-dimensional wood grain, at least 150g / m 2 of the above resin liquid needs to be coated on the surface of the three-dimensional base layer. Therefore, the focus of the present application is shifted to how to form the resin coating amount of 150g / m 2 on the surface of the three-dimensional base layer.

[0118] At present, the most common way of applying resin liquid is to use a roll coater for coating. The applicant has tried to coat a resin liquid with an amount of up to 150g / m 2 on the surface of the three-dimensional base layer at one time, but the applicant found that this one-time coating method requires too much resin liquid to be loaded on a single roll. If a conventional roll is used, the resin liquid will flow down if it is too thick, thereby failing to complete normal production.

[0119] Therefore, in order to solve the above problems, two-roll distributed coating means are adopted in the present application, so that each roll coats one layer of resin liquid, thereby making the total amount of the two layers of resin liquid greater than 150g / m 2The above is enough. This method realizes the coating of a large amount of resin and reduces the resin load pressure of each roller.

[0120] In the prior art, in order to realize the coating of multiple rollers, a roller coating machine with two parallel rollers is usually used. The two rollers of the roller coating machine usually adopt the combination of a positive roller and a reverse roller. In the process of coating the resin liquid on the surface of the plate and pushing the substrate forward, the first roller will generate a certain force on the plate and the resin liquid layer attached to the surface of the plate in the conveying direction of the plate. The force combined with the bristle structure on the surface of the roller will cause a certain deformation of the surface of the resin liquid. When the first layer of resin liquid has not yet been leveled, the second roller has already taken over the plate coated with the uncured resin liquid, and the second roller will generate a force opposite to the conveying direction of the plate on the uncured resin liquid. Therefore, the force will also cause the second layer of resin liquid to deform in the opposite direction. At the same time, due to the speed difference between the second roller and the first roller, the deformation between the first layer of resin liquid and the second layer of resin liquid cannot be offset, but instead, the deformation of the two layers of resin liquid is superimposed, further exacerbating the appearance of the resin liquid imprint. After curing, these imprints will be fixed, which seriously affects the visual effect of the final product. The appearance of these imprints will cause obvious defects in the appearance of the finished product, especially the finished product with shallow lines, that is, there is a pause in the middle of the part coated with resin liquid when viewed from a distance.

[0121] Therefore, based on the existing roller coating machine, a transition treatment step of stopping applying force to the resin liquid is added during the process of covering at least a part of the surface of the three-dimensional substrate layer with any two adjacent layers of resin liquid. In this way, during the process of passing through the first roller, the first roller stops applying force to the entire plate after the end of the force application, and then the plate is conveyed to the second roller without any force being applied to the entire plate. Then, after a long distance, the first layer of resin liquid is leveled, and then the plate is coated by the second roller from the beginning to the end. At this time, due to the small deformation of the second layer of resin liquid, the second layer of resin liquid can be quickly leveled before curing, thereby eliminating the influence of the force and speed difference of the two rollers on the surface morphology of the resin liquid.

[0122] Preferably, during the process of covering at least a part of the surface of the three-dimensional substrate layer with any two adjacent layers of resin liquid, the force application directions of the two adjacent layers of resin liquid are opposite.

[0123] As can be known from the above description, the roller coater will generate a certain force on the resin liquid during the roller coating. Since the resin liquid usually contains high molecular polymers or prepolymers, the molecular chain segments are relatively long, and thus the resin liquid will generate a certain elastic deformation and orientation force under the action of external force. Since the overall process time from coating to curing of the resin liquid is relatively short, the molecular chain segments of the high molecular polymers in the resin liquid have not returned to the initial state before the resin liquid is cured, resulting in that a relatively large internal stress is generated in the middle part of the cured three-dimensional wood grain layer, and thus the middle part of the cured three-dimensional wood grain layer is prone to cracking. Therefore, in order to reduce the generation of internal stress in the middle part of the three-dimensional wood grain layer, the application specifically adjusts the force direction of the two rollers on the adjacent resin liquid to be opposite in the process of covering the surface of at least part of the three-dimensional base layer with the adjacent resin liquid, so that the unhardened second wear-resistant layer can be provided with a force opposite to the internal stress in the second wear-resistant layer during the working process of the second roller, thereby weakening or offsetting the original internal stress of the three-dimensional wood grain layer, and thus the probability of cracking in the middle part of the cured three-dimensional wood grain layer can be reduced.

[0124] Preferably, the embossing liquid is applied to the surface of the resin liquid and / or penetrates into the interior of the resin liquid.

[0125] In the present application, the principle of forming the embossing layer by adding the embossing liquid to the surface of the resin liquid has various forms, including but not limited to ultraviolet covering method, free radical absorption method or volume occupation method.

[0126] The ultraviolet covering method is suitable for UV-curable resin liquid, and the principle is to cover the surface of the unhardened resin liquid with an embossing liquid capable of preventing ultraviolet light from penetrating, so that the resin liquid located below the embossing liquid can remain in a liquid state without curing, and thus the part of the resin liquid that does not cure forms an embossing layer, which is removed by mechanical cleaning or solution washing in the subsequent process, thereby obtaining a three-dimensional wood grain layer with a wood grain structure.

[0127] The free radical absorption method is suitable for resin liquid based on the principle of free radical polymerization, and the principle is to add the embossing liquid to the surface of the unhardened resin liquid or penetrate into the interior of the unhardened resin liquid, so as to absorb the free radicals used for the free radical polymerization of the resin liquid, so that the part of the resin liquid containing the embossing liquid can remain in a liquid state without curing, and thus the part of the resin liquid that does not cure forms an embossing layer, which is removed by mechanical cleaning or solution washing in the subsequent process, thereby obtaining a three-dimensional wood grain layer with a wood grain structure.

[0128] The volume occupation law refers to that when the embossing liquid penetrates into the un-solidified resin liquid, the un-solidified resin liquid is pushed away, and the part of the volume occupied by the embossing liquid only contains the embossing liquid which can be polymerizable or non-polymerizable, and the embossing liquid is removed by mechanical or solvent cleaning, so that the three-dimensional wood grain layer with wood grain structure is obtained.

[0129] Preferably, the embossing liquid at least contains a polymerization inhibitor for preventing the polymerization of the light-crosslinking resin.

[0130] In the preferred embodiment, the polymerization inhibitor is added to the embossing liquid, which can quench the free radicals generated by the photoinitiator under light irradiation, so as to effectively prevent the polymerization of the resin liquid containing the polymerization inhibitor or reduce the curing speed of the resin liquid containing the polymerization inhibitor, so that the resin liquid containing the polymerization inhibitor can still remain in a liquid or semi-solid state, thereby making the embossed layer more easily removed.

[0131] Preferably, the coverage of the topcoat is 20g / m 2 -30g / m 2 .

[0132] In a third aspect, the application also provides the application of the non-polyvinyl chloride wood-plastic board with three-dimensional wood grain as described above in floor panels, wall panels or ceiling panels.

[0133] Therefore, the application has the following beneficial effects:

[0134] (1) The application can effectively prevent the peeling, warping and cracking of the non-polyvinyl chloride wood-plastic board by limiting the surface energy relationship between the adhesive bottom and the non-polyvinyl chloride wood-plastic base layer, thereby effectively improving the stability and durability of the board;

[0135] (2) The non-polyvinyl chloride wood-plastic board has a three-dimensional wood grain that is closer to the visual and tactile three-dimensional wood grain of real wood, thereby meeting the demand for pursuing a more realistic visual and tactile combination;

[0136] (3) The application uses a non-polyvinyl chloride wood-plastic board as a base layer, which can realize the environmentally friendly production and recycling of wood-plastic boards, thereby reducing the consumption of traditional wood, promoting resource conservation and recycling, and meeting the requirements of modern society for environmental protection and sustainable development, and having good social benefits and market prospects. BRIEF DESCRIPTION OF DRAWINGS

[0137] FIG. 1 is a schematic representation of steps (S.1) to (S.2) for preparing a non-polyvinyl chloride wood-plastic board with three-dimensional wood grain according to the embodiment 1 of the application.

[0138] Figure 2 is a chart of the results of the box test of the non-PVC wood-plastic board material of Example 1 of the present application and the adhesive base material of Scheme 1.

[0139] Figure 3 is a chart of the results of the box test of the non-PVC wood-plastic board material of Example 1 of the present application and the adhesive base material of Comparative Scheme 2 (left) and Comparative Scheme 4 (right).

[0140] Figure 4 is a chart of the results of the box test of the PVC wood-plastic board material of Example 1 of the present application and the adhesive base material of Scheme 1.

[0141] Figure 5 is a schematic representation of steps (S.3) - (S.4) in the preparation of the non-PVC wood-plastic board material having three-dimensional wood grain of Example 1 of the present application.

[0142] Figure 6 is a schematic representation of steps (S.5) - (S.8) in the preparation of the non-PVC wood-plastic board material having three-dimensional wood grain of Example 1 of the present application.

[0143] Figure 7 is a schematic representation of steps (S.9) - (S.11) in the preparation of the non-PVC wood-plastic board material having three-dimensional wood grain of Example 1 of the present application.

[0144] Figure 8 is a schematic representation of steps (S.12) - (S.13) in the preparation of the non-PVC wood-plastic board material having three-dimensional wood grain of Example 1 of the present application.

[0145] Figure 9 is a photograph of the non-PVC wood-plastic board material produced using the adhesive base material of Scheme 1 of Example 1 of the present application after the end of the warping test.

[0146] Figure 10 is a photograph of the non-PVC wood-plastic board material produced using the adhesive base material of Comparative Scheme 2 of Example 1 of the present application after the end of the warping test.

[0147] Figure 11 is a photograph of the PVC wood-plastic board material produced using the adhesive base material of Comparative Scheme 5 of Example 1 of the present application after the end of the warping test. DETAILED DESCRIPTION

[0148] The present application will be further described with reference to the following specific examples. Persons skilled in the art will be able to implement the present application based on the description. Furthermore, the examples of the present application described in the following description are generally only a part of the embodiments of the present application, and are not all the embodiments. Therefore, all other embodiments obtained by persons skilled in the art based on the examples in the present application, without making creative efforts, should fall within the scope of protection of the present application.

[0149] The non-polyvinyl chloride wood-plastic plate with three-dimensional wood grain in the present application is different from the existing polyvinyl chloride wood-plastic plate with three-dimensional wood grain in that the material of the base material is replaced, so that the adhesion between the non-polyvinyl chloride wood-plastic base material layer and the three-dimensional surface layer is weak during the preparation process, thereby causing a series of problems such as delamination, warping and cracking of the non-polyvinyl chloride wood-plastic plate after being prepared into a floor. Therefore, the present application is described in detail through a series of embodiments.

[0150] Embodiment 1

[0151] In this embodiment, an adhesion primer capable of stably bonding with a polyolefin resin having a surface energy of not higher than 35 dynes / cm is provided, which is a photocurable resin composition composed of a main resin, an auxiliary resin, an active diluent, a photoinitiator, a filler and an additive.

[0152] In the photocurable resin composition, the main resin is preferably a photocurable resin containing a photosensitive group, a hydrogen bond donor group and a hydrogen bond acceptor group. Further, the main resin contains at least one of an amide group, an imide group, an amino group, a carbamate group, a hydroxyl group and a urea group. The amount of the main resin added is 30-40 wt% of the total mass of the photocurable resin composition.

[0153] The amount of the auxiliary resin added is not less than 25 wt% of the amount of the main resin added and not more than 50 wt% of the amount of the main resin added.

[0154] The amount of the active diluent added is not less than 40 wt% of the amount of the main resin added and not more than 65 wt% of the amount of the main resin added.

[0155] The photoinitiator can be a free radical photoinitiator, and the amount of the photoinitiator added is 3-5 wt% of the total mass of the photocurable resin composition.

[0156] The filler can be any one or a combination of two or more of silicon dioxide, calcium carbonate, aluminum oxide, titanium dioxide, magnesium oxide, talc powder, wollastonite powder, mica powder, precipitated barium sulfate, bentonite, lime powder, and ultra-fine aluminum silicate, and the amount of the filler added is 20-30 wt% of the total mass of the photocurable resin composition.

[0157] The filler can be any one or a combination of two or more of silicon dioxide, calcium carbonate, aluminum oxide, titanium dioxide, magnesium oxide, talc powder, wollastonite powder, mica powder, precipitated barium sulfate, bentonite, lime powder, and ultra-fine aluminum silicate, and the amount of the filler added is 20-30 wt% of the total mass of the photocurable resin composition.

[0158] The auxiliary agent can be a heat stabilizer, a leveling agent, a defoaming agent, etc., and the addition amount is 0.5wt%-1wt% of the total mass of the photocuring resin composition.

[0159] The following Table 1 and Table 2 are some typical schemes and comparative schemes prepared according to the above photocuring resin composition formula.

[0160] Table 1

[0161] Table 2

[0162] The photocuring resin compositions in schemes 1-3 and comparative schemes 1-4 are coated on the surface of the non-polyvinyl chloride wood-plastic board, and the non-polyvinyl chloride wood-plastic board with three-dimensional wood grain is prepared.

[0163] The specific steps of the non-polyvinyl chloride wood-plastic board with three-dimensional wood grain include the steps as shown in Figure 1:

[0164] (S.1) A SPC non-polyvinyl chloride wood-plastic board with length, width and thickness of 1260mm*970mm*4.85mm is placed on the surface of a conveying device moving in a fixed direction, and the non-polyvinyl chloride wood-plastic board (in this embodiment, the formula of the non-polyvinyl chloride wood-plastic board is as follows: polypropylene (surface tension 31mN / m) 47.5wt%, wood powder 15wt%, stone powder 35wt%, antioxidant 1wt%, lubricant 1wt%, ultraviolet resistance agent 0.5wt%);

[0165] (S.2) The non-polyvinyl chloride wood-plastic board first passes through the first roller coater during conveying, and the surface of the roller of the roller coater is attached with the photocuring resin composition in schemes 1-3 and comparative schemes 1-4. During the contact between the non-polyvinyl chloride wood-plastic board and the roller, 12g / m 2 of the photocuring resin composition is coated on the surface of the SPC board, and cured with a UV lamp of 395nm and 8W / cm 2 , so that the primer forms an adhesive bottom.

[0166] In addition, in this embodiment, the inventors also additionally provide comparative scheme 5 which uses a traditional polyvinyl chloride wood-plastic substrate layer and the adhesive bottom material described in scheme 1 for compounding. The formula of the polyvinyl chloride wood-plastic board is as follows: polyvinyl chloride (surface tension 39mN / m) 45wt%, wood powder 15wt%, stone powder 34wt%, antioxidant 2wt%, lubricant 2.5wt%, ultraviolet resistance agent 1.5wt%).

[0167] The adhesion between the non-polyvinyl chloride wood-plastic substrate layer and the attached bottom in the schemes 1-3 and comparative schemes 1-4 was tested according to the method described in ASTM D3359, and the adhesion between the polyvinyl chloride wood-plastic substrate layer and the attached bottom in the comparative scheme 5 was tested, and the test results are shown in Table 3 below.

[0168] Table 3 Adhesion test results of different types of photocurable resin compositions

[0169] The cross-hatch test results of the attached bottom material and the polyvinyl chloride wood-plastic substrate layer in scheme 1 are shown in Figure 2 (the results of scheme 2 and scheme 3 are similar, so they are not shown here). As can be seen from Table 1 and Figure 1, the attached bottom and the PP substrate have good adhesion effect in this application. In Figure 3, the left side is the cross-hatch test result graph of the attached bottom material and the polyvinyl chloride wood-plastic substrate layer in the comparative scheme 2, and the right side is the cross-hatch test result graph of the attached bottom material and the polyvinyl chloride wood-plastic substrate layer in the comparative scheme 4. As can be seen from the results in Figure 3, the adhesion between the attached bottom and the PP substrate is greatly reduced after changing the attached bottom, which is not conducive to the stability and durability of the board. In addition, Figure 4 is the cross-hatch test result graph of the attached bottom material in scheme 1 and the traditional polyvinyl chloride wood-plastic substrate layer in the comparative scheme 5. As can be seen from the figure, it is difficult to use the attached bottom in this application to achieve high-strength adhesion with the traditional polyvinyl chloride wood-plastic substrate layer. This shows that the attached bottom used in this application has good selectivity for polyolefin substrates.

[0170] Taking the attached bottom material in scheme 1 as an example, by attaching different weights of photocurable resin compositions on the surface of the non-polyvinyl chloride wood-plastic board, the effect of the weight of the photocurable resin composition on the adhesion between the non-polyvinyl chloride wood-plastic substrate layer and the attached bottom was explored, and the results are shown in Table 4 below.

[0171] Table 4 Adhesion test results of different adhesion weights

[0172] As shown in Figure 5, (S.3) the non-polyvinyl chloride wood-plastic board obtained in step (S.2) was further passed through a second roller coater, and the surface of the roller of the roller coater was attached with a photocurable white paint (the white paint contains: 50wt% photocurable epoxy HYS01-1, 30wt% titanium white powder, 5wt% photoinitiator 184, 0.5wt% photoinitiator TPO, 14.5wt% diluent hydroxyethyl acrylate), during the contact between the SPC board and the roller, 18g / m 2 of white paint was coated on the surface of the primer, and after curing with a UV lamp of 395nm and 8W / cm 2 , a white paint layer was obtained.

[0173] (S.4) The non-polyvinyl chloride wood-plastic board obtained in the previous step is transported to the first inkjet printer, so that the surface of the paint layer is sprayed with 6-8 g / m 2 of ink by the first inkjet printer, and the ink is cured to form a two-dimensional pattern layer with a wood grain pattern on the surface of the primer layer.

[0174] Further, as shown in FIG. 6, (S.5) the non-polyvinyl chloride wood-plastic board obtained in the previous step is transported to the third roll coater, and 45 g / m 2 of a light-curable resin solution (the resin solution contains: polyurethane acrylate 40 wt%, 5 wt% silica, 15 wt% hydroxyethyl acrylate, 30 wt% alumina, 5 wt% photoinitiator 184, 0.5 wt% photoinitiator TPO, 4.5 wt% diluent) is roll-coated on the surface of the two-dimensional pattern layer, which is sequentially irradiated with a UV lamp of 395 nm and 8 W / cm 2 and a Hg lamp of 160 w / cm 2 to form a wood grain primer layer.

[0175] (S.6) The non-polyvinyl chloride wood-plastic board obtained in the previous step is transported to the fourth roll coater, so that the coating roller of the fourth roll coater roll-coats 80 g / m 2 of a resin solution (the resin solution contains: polyurethane acrylate 40 wt%, 5 wt% silica, 15 wt% hydroxyethyl acrylate, 30 wt% alumina, 5 wt% photoinitiator 184, 0.5 wt% photoinitiator TPO, 4.5 wt% diluent) on the surface of the wood grain primer layer in the direction of transportation of the non-polyvinyl chloride wood-plastic board (the direction of rotation of the roller itself is clockwise).

[0176] (S.7) After coating the first layer of resin solution, the non-polyvinyl chloride wood-plastic board is transported forward along the surface of the conveying device, and it is ensured that the fourth roll coater does not apply any force to the resin solution before being transported to the next roll coater.

[0177] (S.8) The non-polyvinyl chloride wood-plastic board obtained in the previous step is transported to the fifth roll coater, so that the coating roller of the fifth roll coater continues to roll-coat 75 g / m 2 of a resin solution in the direction opposite to the transportation direction of the non-polyvinyl chloride wood-plastic board (the direction of rotation of the roller itself is clockwise).

[0178] Further, as shown in FIG. 7, (S.9) the non-polyvinyl chloride wood-plastic board obtained in the previous step is transported to the second inkjet printer, so that 6 g / m 2 -8 g / m 2embossing liquid (the embossing liquid comprises 45.5wt% of diacrylate monomer PEG600DA, 20.5wt% of p-hydroxyanisole HQMME, 10wt% of 2-tert-butyl hydroquinone MTBHQ, 24wt% of diethylene glycol butyl ether) and allowing the embossing liquid to infiltrate downward into the resin liquid and mix with the resin liquid to form an embossed layer.

[0179] (S.10) The part of the resin liquid on the surface of the non-polyvinyl chloride wood-plastic board obtained in the previous step, except for the embossed layer, is irradiated by a 395nm and 8W / cm 2 UV lamp and a 160w / cm 2 Hg lamp in sequence to achieve deep curing.

[0180] (S.11) The non-polyvinyl chloride wood-plastic board obtained in the previous step is transported to a cleaning device containing a steel brush, so that the embossed layer is brushed off by the steel brush to form a three-dimensional wood grain layer.

[0181] Further, as shown in FIG. 8, (S.12) the non-polyvinyl chloride wood-plastic board obtained in the previous step is passed through a sixth roller coater and a 395nm and 8W / cm 2 UV ultraviolet lamp to coat 12g / m 2 of a first topcoat on the surface of the three-dimensional wood grain layer and cure it to obtain a first topcoat layer;

[0182] (S.13) The non-polyvinyl chloride wood-plastic board obtained in the previous step is passed through a seventh roller coater and a 395nm and 8W / cm 2 UV ultraviolet lamp to coat 12g / m 2 of a second topcoat on the surface of the first topcoat layer and cure it to obtain a second topcoat layer.

[0183] Product testing:

[0184] Product pass rate test: 50 pieces of board in each of the above-mentioned methods, i.e. Scheme 1 to Scheme 3, Comparative Scheme 1 to Comparative Scheme 5, are respectively produced in batches, and whether the board has cracking or delamination phenomenon is observed. Among them, the board with visible quality problems is recorded as unqualified. Then the temperature in the constant temperature drying oven is set to 80℃, and the test sample is placed in the constant temperature drying oven together with an aluminum plate for 6h, and then the test sample is taken out together with the aluminum plate to check the pass rate.

[0185] Warping test: cut the plate into a 240mm*240mm sample, the wear-resistant layer is placed on the aluminum plate, and the average initial warping degree of the plate is measured by the caliper under the condition of 23±2℃ and 50±5% RH; adjust the temperature in the constant temperature drying oven to 80℃, put the sample into the constant temperature drying oven together with the aluminum plate for 6h, then take out the sample together with the aluminum plate, and place it under the condition of 23±2℃ and 50±5% RH for 24h, and then measure the average heating warping degree of the plate by the caliper.

[0186] The test results of product qualification rate test and warping test are shown in Table 5.

[0187] Table 5 Performance test results

[0188] Figure 9 is a plate photo of the non-polyvinyl chloride wood-plastic plate produced by the above method and using the attached bottom material in scheme 1 as raw material after the warping test. As can be seen from Figure 9, after heating at 80℃ for 6h, the plate can still maintain a flat state, indicating that it has good anti-warping performance. Figure 10 is a plate photo of the non-polyvinyl chloride wood-plastic plate produced by the above method and using the attached bottom material in comparative scheme 2 as raw material after the warping test. As can be seen from Figure 9, after heating at 80℃ for 6h, the plate has a certain warping. And Figure 11 is a plate photo of the polyvinyl chloride wood-plastic plate produced by the above method and using the attached bottom material in comparative scheme 5 as raw material after the warping test. As can be seen from the figure, the sample presents strong warping, indicating that compared with polypropylene material, polyvinyl chloride has a lower Vicat softening point, so after heating at 80℃ for 6h, it has a large deformation and warping, indicating that the polyolefin wood-plastic plate has a significant advantage in heat resistance compared with the polyvinyl chloride wood-plastic plate.

[0189] Example 2-3

[0190] The difference between Example 2 and Example 1 is that the formula of the non-polyvinyl chloride wood-plastic plate in Example 1 is replaced, and polypropylene is replaced by polyethylene and poly-4-methyl-1-pentene, and the photocuring resin composition adopts scheme 1.

[0191] The prepared three-dimensional wood grain non-polyvinyl chloride wood-plastic plate is also tested by the same method, and the explanation results are shown in Table 6.

[0192] Table 6

[0193] The specific embodiments described herein are merely illustrative of the spirit of the application. Various modifications or changes in the specific embodiments described herein can occur to those skilled in the art to which the application pertains without departing from the spirit of the application, and it is understood that such modifications or changes are to be considered as within the scope of the application as defined by the appended claims.

Claims

1. A non-polyvinyl chloride wood-plastic panel having a three-dimensional wood grain, characterized in that, Comprising: - a non-polyvinyl chloride wood-plastic substrate layer comprising a polyolefin-based resin having a surface tension of no more than 35 mN / m; - an adhesive primer on one side of the non-polyvinyl chloride wood-plastic substrate layer; wherein, the surface tension of the adhesive primer is less than the surface tension of the polyolefin-based resin, and the difference between the surface tensions is less than 5 mN / m; - a two-dimensional pattern layer attached to the adhesive primer away from the non-polyvinyl chloride wood-plastic substrate layer; wherein, the two-dimensional pattern layer comprises a plurality of connected or unconnected two-dimensional wood grain lines obtained by digital printing; - a three-dimensional wear-resistant layer above the two-dimensional pattern layer, the three-dimensional layer comprising a three-dimensional base layer covering the entire two-dimensional pattern layer and a three-dimensional wear-resistant layer comprising at least a portion or all of a protrusion or a groove corresponding to the two-dimensional wood grain lines or the gaps between the two-dimensional wood grain lines in the two-dimensional pattern layer; - a surface coating layer on the surface of the three-dimensional wear-resistant layer, at least a portion of the surface coating layer being lower than the upper surface of the three-dimensional wear-resistant layer.

2. The non-polyvinyl chloride wood-plastic board with three-dimensional wood grain according to claim 1, wherein, the polyolefin-based resin is any one or a combination of polyethylene, polypropylene, polyisobutylene, ethylene-vinyl acetate copolymer, ethylene-polypropylene copolymer, ethylene-acrylic acid or acrylate copolymer, and poly-4-methyl-1-pentene.

3. The non-polyvinyl chloride wood-plastic board with three-dimensional wood grain according to claim 1, wherein, the adhesion between the non-polyvinyl chloride wood-plastic substrate layer and the adhesive primer is grade 5B according to the method described in ASTM D3359.

4. The non-PVC wood-plastic panel with three-dimensional wood grain according to claim 1 or 2 or 3, characterized in that, the non-polyvinyl chloride wood-plastic substrate layer further comprises fillers and processing aids.

5. The non-polyvinyl chloride wood-plastic board with three-dimensional wood grain according to claim 4, wherein, the fillers are wood powder and / or stone powder.

6. The non-polyvinyl chloride wood-plastic board with three-dimensional wood grain according to claim 1, wherein, the adhesive primer is obtained by curing a photocurable resin composition; the photocurable resin composition comprises a main resin having a photosensitive group; the main resin further comprises a hydrogen bond donor group and a hydrogen bond acceptor group for forming hydrogen bonds.

7. The non-polyvinyl chloride wood-plastic board with three-dimensional wood grain according to claim 6, wherein, the photocurable resin composition has a dynamic viscosity of 80 seconds to 250 seconds.

8. The non-polyvinyl chloride wood-plastic board with three-dimensional wood grain according to claim 6, wherein, The adhesive bottom has a weight of 10 g / m 2 - 15 g / m 2 .

9. The non-polyvinyl chloride wood-plastic board with three-dimensional wood grain according to claim 6, wherein, the main resin comprises any one of an amide group, an imide group, an amino group, a carbamate group, a hydroxyl group, and a urea group.

10. The non-polyvinyl chloride wood-plastic board with three-dimensional wood grain according to claim 6, wherein, the photocurable resin composition further comprises an auxiliary resin having a photosensitive group and an active diluent; at least one of the auxiliary resin and the active diluent comprises a hydrogen bond acceptor group.

11. The non-PVC wood-plastic panel with three-dimensional wood grain according to claim 10, wherein the additive amount of the main resin is 30wt%-40wt% of the total mass of the photocuring resin composition; and the additive amount of the auxiliary resin is not higher than 50wt% of the additive amount of the main resin.

12. The non-PVC wood-plastic panel with three-dimensional wood grain according to claim 11, wherein the additive amount of the auxiliary resin is not lower than 25wt% of the additive amount of the main resin.

13. The non-PVC wood-plastic panel with three-dimensional wood grain according to claim 11, wherein the additive amount of the active diluent is not lower than 40wt% of the additive amount of the main resin.

14. The non-PVC wood-plastic panel with three-dimensional wood grain according to claim 11, wherein the active diluent contains at least two branched chains containing acrylic acid structure.

15. The non-PVC wood-plastic panel with three-dimensional wood grain according to claim 14, wherein the active diluent is any one of tripropylene glycol diacrylate, trimethylolpropane triacrylate, and pentaerythritol triacrylate.

16. The non-PVC wood-plastic panel with three-dimensional wood grain according to any one of claims 6-15, wherein the photocuring resin composition further comprises a photoinitiator, a filler, and an auxiliary agent.

17. The non-PVC wood-plastic panel with three-dimensional wood grain according to claim 16, wherein the additive amount of the photoinitiator is 3wt%-5wt% of the total mass of the photocuring resin composition; the additive amount of the filler is 20wt%-30wt% of the total mass of the photocuring resin composition; and the additive amount of the auxiliary agent is 0.5wt%-1wt% of the total mass of the photocuring resin composition.

18. The non-PVC wood-plastic panel with three-dimensional wood grain according to claim 16, wherein the photoinitiator is a free radical photoinitiator.

19. The non-PVC wood-plastic panel with three-dimensional wood grain according to claim 16, wherein the filler is any one or a combination of silicon dioxide, calcium carbonate, aluminum oxide, titanium dioxide, magnesium oxide, talc powder, wollastonite powder, mica powder, precipitated barium sulfate, bentonite, calcium carbonate powder, and ultra-fine aluminum silicate.

20. The non-PVC wood-plastic panel with three-dimensional wood grain according to any one of claims 6-15, wherein the adhesive base contains a color hiding agent for hiding the color of the non-PVC wood-plastic substrate layer; and the two-dimensional pattern layer is printed on the surface of the adhesive base.

21. The non-PVC wood-plastic panel with three-dimensional wood grain according to any one of claims 6-15, wherein the surface of the adhesive base away from the non-PVC wood-plastic substrate layer is further covered with a color paint layer containing a color hiding agent; and the two-dimensional pattern layer is printed on the surface of the color paint layer. ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ 22. The non-PVC wood-plastic panel with three-dimensional wood grain according to any one of claims 6-15, wherein the adhesive bottom is further covered with a color hiding film for hiding the color of the non-PVC wood-plastic base layer on the surface away from the non-PVC wood-plastic base layer; and the two-dimensional pattern layer is printed on the surface of the color hiding film. The method comprises the following steps: providing a non-PVC wood-plastic base layer; 23. A method for producing the non-polyvinyl chloride wood-plastic board having a three-dimensional wood grain according to any one of claims 1 to 22, characterized by, applying a layer of photocuring resin composition on the surface of the non-PVC wood-plastic base layer, and curing the photocuring resin composition to obtain the adhesive bottom, so that the difference in surface energy between the adhesive bottom and the non-PVC wood-plastic base layer is less than 5 mN / m; printing on the adhesive bottom to obtain the two-dimensional pattern layer; three-dimensional printing on the surface of the two-dimensional pattern layer to obtain the three-dimensional wear-resistant layer; applying a topcoat on the surface of the three-dimensional wear-resistant layer, and curing the topcoat to obtain the topcoat layer.

24. The method according to claim 23, wherein the photocuring resin composition has a dynamic viscosity of 80-250 seconds.

25. The method according to claim 23 or 24, wherein the two-dimensional pattern layer is directly printed on the surface of the adhesive bottom.

26. The method according to claim 25, wherein the photocuring resin composition further comprises a color hiding agent for hiding the color of the non-PVC wood-plastic base layer.

27. The method according to claim 23 or 24, wherein before printing the two-dimensional pattern layer, a color paint layer is applied on the surface of the adhesive bottom, and the color paint layer is cured to form the color paint layer, and the two-dimensional pattern layer is directly printed on the surface of the color paint layer. The application amount of the photocurable resin composition is 10 g / m 2 - 15 g / m 2 .

28. The method according to claim 23 or 24, wherein before printing the two-dimensional pattern layer, a color hiding film for hiding the color of the non-PVC wood-plastic base layer is attached on the surface of the adhesive bottom by heat bonding, and the two-dimensional pattern layer is directly printed on the surface of the color hiding film.

29. Use of the non-PVC wood-plastic panel with three-dimensional wood grain according to any one of claims 1-22 in floor panels, wall panels or ceiling panels. ​ ​ ​ ​ ​ ​ ​

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