Decorative material having 3D texture structure, preparation method therefor, and use thereof

Abstract

A preparation method for a decorative material having a 3D texture structure, comprising the following steps: performing digital printing on a pre-treated substrate to obtain a 2D pattern layer on the surface of the substrate; applying a photocurable coating onto the surface of the 2D pattern layer and performing preliminary curing; then inkjet-printing a texture developing solution onto the preliminarily cured surface and performing secondary curing to obtain a cured coating, wherein the cured coating comprises a hardened portion and an unhardened portion; and after the unhardened portion of the cured coating is removed by means of polishing and brushing, applying a top coating, so as to obtain a decorative material having a 3D texture structure. In the preparation method, textures of different widths and depths can be obtained by means of preliminary curing of a coating and absorption of ultraviolet rays by a developing solution, and then a microscopically "rough" but visually smooth morphology is obtained by means of polishing and brushing. Thus, the obtained 3D texture structure resembles natural textures. The present invention further relates to a decorative material having a 3D texture structure, and a use of the decorative material having the 3D texture structure in flooring or decorative panels.

Description

A decorative material with 3D texture structure, its preparation method and application

[0001] This application claims priority to Chinese Patent Application No. CN202411818314.2, filed on December 11, 2024, entitled "A Decorative Material with a 3D Texture Structure and Its Preparation Method and Application", the entire contents of which are incorporated herein by reference. Technical Field

[0002] This application relates to the field of decorative materials technology, specifically to a decorative material with a 3D textured structure, its preparation method, and its application. Background Technology

[0003] Currently, two-dimensional decorative effects are no longer sufficient for surface decoration of materials, and three-dimensional decoration is gaining more popularity. Three-dimensional decorative surface technology often utilizes the inherent properties of decorative materials to create three-dimensional textures on flat materials using physical or mechanical methods. For example, textures can be created by pressing thermoplastic materials into molds at high temperatures, or by laser engraving. However, this method generally involves high energy consumption, complex processes, high costs, and insufficient texture realism.

[0004] Newer technologies utilize advanced computer control and digital printing techniques combined with novel curing technologies during pattern or coating formation, aiming to achieve more realistic biomimetic three-dimensional textures with simpler process paths. However, the results are not ideal. For example, "additive inks" create raised textures by piling up ink through inkjet printing. Due to the low viscosity and high fluidity of the ink, it is difficult to achieve the desired build-up thickness, resulting in significant differences from natural textures. Another example is "subtractive inks," which use corrosive chemicals to partially remove ink or coatings, creating recessed textures. This method requires hazardous chemicals and easily causes environmental pollution.

[0005] Another method uses an "embossing liquid" to create textures, as seen in patents CN110177691A, CN114015286B, and CN116533666A. This involves inkjet printing an "embossing liquid" onto an uncured UV coating. The embossing liquid is a non-curable liquid or a mixture containing polymerization inhibitors or UV absorbers, resulting in a failure to harden after curing or a significantly lower hardness than the underlying coating. The embossing liquid is then removed to form the texture; the recessed portion represents the entire embossing liquid component. This method requires a very high degree of matching between the underlying coating and the embossing liquid in terms of surface energy, density, and diffusion coefficient; otherwise, an effective texture cannot be formed. Furthermore, the final three-dimensional shape of the texture is the same as the three-dimensional shape of the embossing liquid, meaning the texture is relatively rounded around the edges, still showing a significant difference from the three-dimensionality of natural textures. Summary of the Invention

[0006] To address the problems existing in the prior art, this application provides a decorative material with a 3D textured structure, its preparation method, and its application. The decorative material prepared by the method provided in this application exhibits a realistic 3D texture structure with minimal difference from natural textures.

[0007] To achieve the above-mentioned objectives, this application provides the following technical solution:

[0008] This application provides a method for preparing a decorative material with a 3D textured structure, including the following steps:

[0009] The pre-treated substrate is digitally printed to obtain a 2D pattern layer on the substrate surface.

[0010] A photocurable coating is applied to the surface of the 2D pattern layer and pre-cured. Then, a second curing is performed on the pre-cured surface using an inkjet printing texture developer to obtain a cured coating. The cured coating includes a hardened portion and an unhardened portion.

[0011] After removing the uncured portions of the hardened coating through polishing and wire drawing, a topcoat is applied to obtain a decorative material with a 3D textured structure.

[0012] Preferably, the pretreatment includes one or more of leveling, filling, attaching, and masking.

[0013] Preferably, the digital printing includes UV ink printing, water-based ink printing, water-based UV ink printing, or solvent-based ink printing.

[0014] Preferably, after obtaining the 2D pattern layer and before applying the light-cured coating, the method further includes applying a primer and / or a wear-resistant coating to the surface of the 2D pattern layer and then curing it.

[0015] Preferably, the components of the photocurable coating include a photocurable resin and a first photoinitiator;

[0016] The photocurable resin includes acrylic resin;

[0017] The acrylic resin includes one or more of polyurethane acrylic resin, epoxy acrylic resin, polyester acrylic resin, polyether acrylic resin, and pure acrylic resin.

[0018] Preferably, the wavelength of the maximum absorption peak of the first photoinitiator is 350–420 nm;

[0019] The mass of the first photoinitiator is 0.001% to 5% of the mass of the photocurable coating.

[0020] Preferably, the first photoinitiator comprises at least one of 2,4,6-trimethylbenzoyl diphenylphosphine oxide, phenyl bis(2,4,6-trimethylbenzoyl)phosphine oxide, (2,4,6-trimethylbenzoyl)bis(p-tolyl)phosphine oxide) and ethyl 2,4,6-trimethylbenzoyl phenylphosphonate.

[0021] Preferably, the components of the photocurable coating further include at least one of an active diluent, a coating additive, and a second photoinitiator;

[0022] The mass of the second photoinitiator is 0.5% to 5% of the mass of the photocurable coating;

[0023] The wavelength of the maximum absorption peak of the second photoinitiator is 200–350 nm.

[0024] Preferably, the second photoinitiator includes at least one of 1-hydroxycyclohexylphenyl ketone, 2-hydroxy-2-methyl-1-phenyl-1-propanone, methyl benzoylformate, oxobis(ethane-2,1-diyl)bis(2-oxo-2-phenylacetic acid ester), benzophenone, 4-chlorobenzophenone, and 4-methylbenzophenone.

[0025] Preferably, the preliminary curing is performed by irradiating the photocurable coating with a preliminary curing light source, wherein the main wavelength of the ultraviolet light generated by the preliminary curing light source is 350-420nm;

[0026] The thickness of the photocurable coating is 10–300 μm.

[0027] Preferably, the texture developer includes a third photoinitiator;

[0028] The wavelength of the maximum absorption peak of the third photoinitiator is 200–420 nm;

[0029] The third photoinitiator includes one or more of the following: 2,4,6-trimethylbenzoyl diphenylphosphine oxide, (2,4,6-trimethylbenzoyl)di(p-tolyl)phosphine oxide, ethyl 2,4,6-trimethylbenzoyl phenylphosphine acid, phenyl bis(2,4,6-trimethylbenzoyl)phosphine oxide, 1-hydroxycyclohexylphenyl ketone, 2-hydroxy-2-methyl-1-phenyl-1-propanone, methyl benzoylformate, oxo-bis(ethane-2,1-diyl)bis(2-oxo-2-phenylacetic acid), benzophenone, 4-chlorobenzophenone, and 4-methylbenzophenone.

[0030] Preferably, the mass percentage of the third photoinitiator in the texture developer is ≥20%.

[0031] Preferably, the texture developer further includes at least one of acrylic resin, reactive diluent, and coating additives.

[0032] Preferably, the reactive diluent comprises 1,6-hexanediol diacrylate;

[0033] The mass percentage of acrylic resin in the texture developing solution is ≤20%;

[0034] The reactive diluent in the texture developer contains ≤70% by mass.

[0035] Preferably, when using the inkjet printing texture developer, the texture developer is consistent with the pattern and position of the 2D pattern layer.

[0036] Preferably, the second curing is performed by irradiating the coated texture developer with a second curing light source, and the light source for the second curing is one or more of gallium lamps, mercury lamps, halogen lamps and electrodeless lamps.

[0037] Preferably, the removal of unhardened portions of the cured coating by polishing and wire drawing is performed using a polishing and wire drawing machine; the polishing and wire drawing machine includes 4 to 10 sets of high-hardness brushes and 2 to 6 sets of low-hardness brushes; the high-hardness brushes are steel brushes, and the low-hardness brushes are nylon brushes or composite brushes, wherein the composite brushes are made of steel and nylon.

[0038] The polishing and wire drawing process includes sequentially performing a first polishing and wire drawing and a second polishing and wire drawing. The first polishing and wire drawing is performed using the high-hardness brush, and the second polishing and wire drawing is performed using the low-hardness brush.

[0039] Preferably, the coating layer consists of 1 to 3 coats.

[0040] This application also provides decorative materials with 3D textured structures prepared by the preparation method described in the above technical solution.

[0041] This application also provides the application of the decorative materials with 3D textured structures described in the above technical solutions in flooring or decorative panels.

[0042] This application provides a method for preparing a decorative material with a 3D textured structure, comprising the following steps: digitally printing a pre-treated substrate to obtain a 2D pattern layer on the substrate surface; coating the surface of the 2D pattern layer with a photocurable coating and performing preliminary curing; then inkjet printing a texture developer on the pre-cured surface for a second curing to obtain a cured coating; the cured coating includes a hardened portion and an uncured portion; after removing the uncured portion of the cured coating by polishing and wire drawing, a topcoat is applied to obtain a decorative material with a 3D textured structure. The 3D texture formation process and three-dimensional morphology of this application are easier to control. After the photocurable coating of this application is pre-cured, the surface is already semi-cured or has a high viscosity. The texture developer does not need to penetrate into the lower coating layer to obtain the texture, unlike the "embossing liquid" in the prior art, and does not need to control a series of parameters such as density, diffusion coefficient, and surface tension. This application achieves textures of varying widths and depths through a combination of initial coating curing and ultraviolet light absorption by a developing solution. During the polishing and brushing process, a rough texture shape is first created, followed by trimming of burrs to achieve a more aesthetically pleasing texture. The brushing depth is controlled to gradually increase from shallow to deep, resulting in a finer texture. Ultimately, the texture appears "rough" under a microscopic scale but smooth to the naked eye, more closely resembling natural textures and enabling true synchronous texture matching. This application features a simple process, strong controllability, and ease of mass production. Attached Figure Description

[0043] Figure 1 is a flowchart of the preparation method of the decorative material with 3D texture structure provided in this application;

[0044] Figure 2 is a schematic diagram of the texture formation process in the decorative material of this application. Detailed Implementation

[0045] This application provides a method for preparing a decorative material with a 3D textured structure, including the following steps:

[0046] The pre-treated substrate is digitally printed to obtain a 2D pattern layer on the substrate surface.

[0047] A photocurable coating is applied to the surface of the 2D pattern layer and pre-cured. Then, a second curing is performed on the pre-cured surface using an inkjet printing texture developer to obtain a cured coating. The cured coating includes a hardened portion and an unhardened portion.

[0048] After removing the uncured portions of the hardened coating through polishing and wire drawing, a topcoat is applied to obtain a decorative material with a 3D textured structure.

[0049] This application involves digitally printing a pre-treated substrate to obtain a 2D pattern layer on the substrate surface. As one embodiment, the pre-treatment includes one or more of leveling, filling, attaching, and masking.

[0050] This application does not specifically limit the pretreatment steps; those skilled in the art can select appropriate pretreatment steps based on the different substrates. As one embodiment, the substrate includes a plastic substrate, inorganic board, wood substrate, metal substrate, or composite substrate, and is more preferably a PVC substrate, PET substrate, calcium silicate board, or magnesium oxide board. In a specific embodiment of this application, the substrate is preferably an SPC substrate, particleboard, or calcium silicate board.

[0051] In this application, when the substrate is a PVC substrate, the pretreatment process preferably includes: polishing and dust removal of the substrate, applying a primer and curing it, and then applying two coats of masking white and curing them. In this application, the primer is preferably BPVC-1335, and the coating amount is preferably 8 g / m³. 2 The preferred white base coat is BMZ-809W, and the preferred coating amount for each coat is 22g / m². 2 .

[0052] In this application, when the substrate is particleboard, the pretreatment process preferably includes: polishing and dust removal of the substrate, and then coating it with a penetration-enhancing primer Jetgood4281 at a coating weight of 30 g / m². 2 After curing, apply two coats of BMZ-303A filler putty, 40g / m² per coat. 2 After each coat is cured, apply two more coats of white base coat BMZ-809W, each coat 22g / m². 2 Each coat of paint is cured after application.

[0053] In this application, when the substrate is a calcium silicate board, the pretreatment process preferably includes: polishing and dust removal of the substrate, and then coating it with a penetration-enhancing primer BMZ-5100 at a coating weight of 35 g / m². 2 After curing, apply two coats of BMZ-303A filler putty, 40g / m² per coat. 2 After each coat is cured, apply two more coats of white base coat BMZ-809W, each coat 22g / m². 2 Each coat of paint is cured after application.

[0054] As one implementation method, the digital printing includes UV ink printing, water-based ink printing, water-based UV ink printing, or solvent-based ink printing. In a specific embodiment, the digital printing is preferably UV ink printing.

[0055] After obtaining the 2D pattern layer, this application coats the surface of the 2D pattern layer with a photocurable coating, performs preliminary curing, and then performs a second curing on the pre-cured surface with an inkjet printing texture developer to obtain a cured coating; the cured coating includes a hardened portion and an uncured portion.

[0056] In one implementation, after obtaining the 2D pattern layer and before applying the UV-cured coating, a primer and / or abrasion-resistant coating are applied to the surface of the 2D pattern layer, followed by curing. In this application, when the primer and abrasion-resistant coating are applied to the surface of the 2D pattern layer, the primer preferably contacts the 2D pattern layer. This application does not specifically limit the composition of the primer and abrasion-resistant coating; any composition well-known to those skilled in the art can be used. In practical applications, the decorative material obtained by adding a primer and / or abrasion-resistant coating can be used as flooring.

[0057] In a specific embodiment of this application, the primer is preferably BPVC-1335, and the coating amount is preferably 8 g / m². 2 The preferred material for the wear-resistant coating is wear-resistant primer BMZ-323C, with a coating weight of 60 g / m². 2 .

[0058] In one embodiment, the components of the photocurable coating include a photocurable resin and a first photoinitiator. In one embodiment, the photocurable resin includes an acrylic resin, which preferably includes one or more of polyurethane acrylic resin, epoxy acrylic resin, polyester acrylic resin, polyether acrylic resin, and pure acrylic resin. In this application, the epoxy acrylic resin is preferably TUE75, and the polyurethane acrylic resin is preferably TUN208, TUN88, or TUN187. In one embodiment, the wavelength of the maximum absorption peak of the first photoinitiator is 350–420 nm. In one embodiment, the first photoinitiator includes at least one of 2,4,6-trimethylbenzoyl diphenylphosphine oxide, phenyl bis(2,4,6-trimethylbenzoyl)phosphine oxide, (2,4,6-trimethylbenzoyl)di(p-tolyl)phosphine oxide, and ethyl 2,4,6-trimethylbenzoyl phenylphosphonate.

[0059] In one embodiment, the mass of the first photoinitiator is 0.001% to 5% of the mass of the photocurable coating.

[0060] In one embodiment, the components of the photocurable coating further include at least one of a reactive diluent, a coating additive, and a second photoinitiator. In this application, the reactive diluent preferably includes tripropylene glycol diacrylate or dipropylene glycol diacrylate.

[0061] In one embodiment, the wavelength of the maximum absorption peak of the second photoinitiator is 200–350 nm. In another embodiment, the second photoinitiator includes at least one of 1-hydroxycyclohexylphenyl ketone (184), 2-hydroxy-2-methyl-1-phenyl-1-propanone (1173), methyl benzoylformate (MBF), oxo-bis(ethane-2,1-diyl)bis(2-oxo-2-phenylacetic acid) (754), benzophenone (BP), 4-chlorobenzophenone (CBP), and 4-methylbenzophenone (MBP).

[0062] In one embodiment, the mass of the second photoinitiator is 0.5 to 5% of the mass of the photocurable coating. In this application, the first photoinitiator is a photoinitiator that absorbs a longer wavelength, which enables the bottom of the coating to cure well; the second photoinitiator is a photoinitiator that absorbs a shorter wavelength, which helps the surface to cure, so that the surface can achieve better hardness after the second curing.

[0063] In one implementation, the preliminary curing is performed by irradiating the photocurable coating with a preliminary curing light source. The primary wavelength of the ultraviolet light generated by the preliminary curing light source is 350–420 nm. The preliminary curing light source includes a UV-LED lamp or a gallium lamp, and the wavelength of the UV-LED lamp is 360–420 nm. In a specific embodiment, the preliminary curing light source is preferably a UV-LED lamp. In this application, the purpose of the preliminary curing is to achieve cross-linking and hardening of the bottom layer of the photocurable coating, while the surface layer has low hardness or is only in a gel state.

[0064] In one implementation, the thickness of the photocurable coating after initial curing is 10–300 μm; in another implementation, the thickness is 20–200 μm; and in a specific embodiment, the thickness can be 30–150 μm. In this application, the thickness of the photocurable coating and the effect of initial curing largely determine the depth of the final texture. In this application, the UV-LED lamp only provides long-wave ultraviolet light, which, combined with the first photoinitiator and the surface oxygen inhibition effect, results in a very low degree of curing of the surface coating, but the bottom coating can cross-link and harden.

[0065] In one embodiment, the texture developer includes a third photoinitiator. In one embodiment, the wavelength of the maximum absorption peak of the third photoinitiator is 200–420 nm. In one embodiment, the third photoinitiator includes one or more of 2,4,6-trimethylbenzoyl diphenylphosphine oxide, (2,4,6-trimethylbenzoyl)di(p-tolyl)phosphine oxide, ethyl 2,4,6-trimethylbenzoylphenylphosphine acid, phenylbis(2,4,6-trimethylbenzoyl)phosphine oxide, 1-hydroxycyclohexylphenyl ketone (184), 2-hydroxy-2-methyl-1-phenyl-1-propanone (1173), methyl benzoylformate (MBF), oxy-bis(ethane-2,1-diyl)bis(2-oxo-2-phenylacetic acid) (754), benzophenone (BP), 4-chlorobenzophenone (CBP), and 4-methylbenzophenone (MBP).

[0066] In this application, the optimal photoinitiator content in the texture developer is to ensure that all ultraviolet light irradiated onto the texture developer during the second curing is absorbed. As one embodiment, the mass percentage of the third photoinitiator in the texture developer is ≥20%; as another embodiment, the mass percentage of the third photoinitiator in the texture developer is ≥50%.

[0067] In one embodiment, the texture developer further includes at least one of acrylic resin, reactive diluent, and coating additives. In this application, the reactive diluent preferably includes 1,6-hexanediol diacrylate.

[0068] In one embodiment, the acrylic resin content in the texture developer is ≤20% by mass. In another embodiment, the reactive diluent content in the texture developer is ≤70% by mass; in a specific embodiment, the reactive diluent content in the texture developer is ≤50% by mass.

[0069] In one implementation, when the inkjet printing texture developer is used, the texture developer is consistent with the pattern and position of the 2D pattern layer, so that the final 3D texture can achieve a synchronous texture matching effect.

[0070] In one embodiment, the second curing is performed by irradiating the coated texture developer with a second curing light source, and the light source for the second curing is one or more of gallium lamps, mercury lamps, halogen lamps, and electrodeless lamps.

[0071] After obtaining the cured coating, this application removes the uncured portion of the cured coating by polishing and brushing, and then applies a topcoat to obtain a decorative material with a 3D textured structure.

[0072] As one implementation method, the unhardened portion of the cured coating is removed by polishing and wire drawing using a polishing and wire drawing machine.

[0073] In another embodiment, the polishing and wire drawing machine includes 4-10 sets of high-hardness brushes and 2-6 sets of low-hardness brushes; the high-hardness brushes are preferably steel brushes, and the low-hardness brushes are preferably nylon brushes or composite brushes, with the composite brushes preferably being made of a combination of steel and nylon. In this application, the polishing and wire drawing preferably includes sequentially performing a first polishing and wire drawing and a second polishing and wire drawing, wherein the first polishing and wire drawing is preferably performed using the high-hardness brushes, and the second polishing and wire drawing is preferably performed using the low-hardness brushes. In this application, during the polishing and wire drawing process, a rough texture shape is first drawn out using a high-hardness steel brush, and then the burrs are trimmed using a low-hardness nylon brush or composite brush to obtain a more aesthetically pleasing texture. In one embodiment, the wire drawing depth is controlled to gradually increase from shallow to deep to draw out a finer texture, ultimately forming a microscopically "rough" but visually smooth morphology around the texture, which is closer to a natural texture.

[0074] In one embodiment, the topcoat layer consists of 1 to 3 coats.

[0075] In this application, when the decorative material is applied to flooring, the topcoat is a matte coating. The preparation of the matte coating preferably includes: applying a first matte primer BPVC-1435 with a coating weight of 8 g / m². 2 After curing, apply a second matte topcoat BPVC-1035-05 and cure it, with a coating weight of 10g / m². 2 After the matte coating is prepared, post-processing is preferably included, which preferably includes trimming, cutting, and grooving in sequence.

[0076] In this application, when the decoration is preferably applied to furniture, the surface coating is preferably BMZ-1012-30, and the coating amount is preferably 12g / m². 2 .

[0077] In this application, when the decorative material is preferably applied to a wall surface, the topcoat is preferably a two-coat BMZ-8240-10 topcoat, with each coat preferably having a coverage of 6 g / m². 2 .

[0078] Figure 1 is a flowchart of the preparation method of the decorative material with 3D texture structure provided in this application. As shown in Figure 1, the substrate after pretreatment is digitally printed to obtain a 2D pattern layer on the substrate surface; a photocurable coating is applied to the surface of the 2D pattern layer for preliminary curing, and then a texture developer is sprayed onto the pre-cured surface for a second curing to obtain a cured coating; then the uncured coating portion in the cured coating is removed by polishing and wire drawing to form a 3D texture structure.

[0079] As shown in Figure 2, the formation mechanism of the 3D texture provided by the preparation method of this application is as follows: The initially cured photocurable coating forms a cross-linked and hardened bottom layer, while the surface layer has low hardness or is only in a gel state. After inkjet printing texture developer on the photocurable coating, a second curing is performed. Since the texture developer contains a large amount of photoinitiator, the ultraviolet light directly hitting the texture developer is absorbed by the photoinitiator and cannot penetrate the developer to reach the underlying photocurable coating. This ensures that the "uncured coating part" under the developer will not further cross-link and harden, and will remain in a state of low hardness. Other photocurable coating parts not covered by the developer are successfully fully cured under the action of ultraviolet light during the second curing, reaching a higher hardness. Therefore, areas with obvious "hardness differences" are formed. Since the main raw material of the texture developer is a non-polymerizable photoinitiator, it is still in a liquid or semi-solid state after the action of ultraviolet light during the second curing. Under the action of the steel brush of the subsequent polishing and wire drawing machine, the texture developer and the "uncured coating part" below it are mechanically removed, thus forming the texture. Existing ultraviolet light sources contain a large amount of oblique ultraviolet light. The effect of oblique ultraviolet light causes the "uncured part of the coating" to form a shape similar to the "V" shown in the figure. The size of the coverage area of ​​the texture developer determines the width and depth of the texture. Therefore, 3D textures with different shapes and varying depths and widths can be obtained in the end.

[0080] This application also provides decorative materials with 3D textured structures prepared by the preparation method described in the above technical solution.

[0081] This application also provides the application of the decorative materials with 3D textured structures described in the above technical solutions in flooring or decorative panels.

[0082] In one embodiment, the decorative panel includes furniture or a wall panel; the furniture includes a cabinet.

[0083] The technical solutions provided in this application will be described in detail below with reference to the embodiments, but they should not be construed as limiting the scope of protection of this application.

[0084] Example 1

[0085] After polishing and dust removal, the SPC substrate (a type of PVC substrate) is coated with primer BPVC-1335 at a coating weight of 8 g / m². 2 After curing, apply two coats of white base coat BMZ-809W to cover the surface, each coat using 22g / m². 2 Each coating is cured after application, and then digital printing is performed using UV ink to obtain a 2D pattern layer on the substrate surface.

[0086] A primer BPVC-1335 is applied to the surface of the 2D pattern layer at a coating weight of 8 g / m². 2After curing, apply abrasion-resistant primer BMZ-323C with a coating amount of 60g / m². 2 After curing, a UV-curable coating is applied for preliminary curing. The UV-curable coating has a thickness of 150 μm and contains, by weight percentage, 67% epoxy acrylate resin TUE75, 30% reactive diluent tripropylene glycol diacrylate, 0.5% primary photoinitiator 2,4,6-trimethylbenzoyl diphenylphosphine oxide (with a maximum absorption peak wavelength of 380 nm), and 2.5% secondary photoinitiator MBF (with maximum absorption peak wavelengths of 255 nm and 325 nm). The preliminary curing light source is a UV-LED lamp with a main emission wavelength of 395 nm.

[0087] Then, the texture developer is printed onto the pre-cured surface using an inkjet printer. The texture developer is controlled to align with the desired texture location, i.e., with the corresponding position of the 2D pattern layer. A second curing is performed using a mercury lamp to obtain a cured coating. The texture developer contains, by weight percentage, 50% photoinitiator MBF, 20% photoinitiator ethyl 2,4,6-trimethylbenzoylphenylphosphonate, and 30% reactive diluent 1,6-hexanediol diacrylate.

[0088] The unhardened parts of the cured coating are then removed by polishing and wire drawing to form a texture. Polishing and wire drawing is done using a polishing and wire drawing machine, which contains 10 sets of steel brushes and 2 sets of composite brushes. The composite brushes are made of steel and nylon. During polishing and wire drawing, the high-hardness steel brushes first draw out a rough texture shape (i.e., the first polishing and wire drawing), and then the low-hardness composite brushes trim the burrs (i.e., the second polishing and wire drawing) to obtain a more beautiful texture.

[0089] Finally, two coats of topcoat are applied to obtain a decorative material with a 3D textured structure. The topcoat is a matte finish, and to achieve a uniform matte effect, the topcoat includes a first coat of matte primer BPVC-1435 with a coverage of 8 g / m². 2 After curing, apply a second matte topcoat BPVC-1035-05 and cure it, with a coating weight of 10g / m². 2 After trimming, cutting, and tenoning processes, flooring with 3D texture is obtained.

[0090] The primer BPVC-1335, the cover coat BMZ-809W, the abrasion-resistant primer BMZ-323C, the epoxy acrylic resin TUE75, the matte primer BPVC-1435, and the matte topcoat BPVC-1035-05 are all from Bonfer New Materials Co., Ltd.

[0091] Example 2

[0092] After polishing, leveling, and dust-removing the particleboard (a type of wood substrate), apply a penetrating and reinforcing primer, Jetgood4281, with a coating weight of 30g / m². 2 After curing, apply two coats of BMZ-303A filler putty, 40g / m² per coat. 2 After each coat is cured, apply two more coats of white base coat BMZ-809W, each coat 22g / m². 2 Each coating is cured after application, and then digital printing is performed using UV ink to obtain a 2D pattern layer on the substrate surface.

[0093] A photocurable coating is applied to the surface of the 2D pattern layer and then pre-cured. The photocurable coating has a thickness of 50 μm and contains, by weight percentage, 42% polyurethane acrylate resin TUN187, 20% epoxy acrylate resin TUE75, 35% reactive diluent tripropylene glycol diacrylate, 1% first photoinitiator ethyl 2,4,6-trimethylbenzoylphenylphosphonate (maximum absorption peak wavelength 366 nm), and 2% second photoinitiator 184 (maximum absorption peak wavelength 260 nm). The pre-curing light source is a UV-LED lamp with a main emission wavelength of 395 nm.

[0094] Then, the texture developer is printed onto the pre-cured surface using an inkjet printer. The texture developer is controlled to align with the desired texture location, i.e., with the corresponding position of the 2D pattern layer. A second curing is performed using a mercury lamp to obtain a cured coating. The texture developer contains, by weight percentage, 50% photoinitiator 1173, 20% photoinitiator ethyl 2,4,6-trimethylbenzoylphenylphosphonate, 20% photoinitiator CBP, and 10% reactive diluent 1,6-hexanediol diacrylate.

[0095] The unhardened parts of the cured coating are then removed by polishing and wire drawing to form a texture. Polishing and wire drawing is done using a polishing and wire drawing machine, which contains 6 sets of steel brushes and 4 sets of composite brushes. The composite brushes are made of steel and nylon. During polishing and wire drawing, the high-hardness steel brushes first draw out a rough texture shape (i.e., the first polishing and wire drawing), and then the low-hardness composite brushes trim the burrs (i.e., the second polishing and wire drawing) to obtain a more beautiful texture.

[0096] Finally, a topcoat is applied and cured to obtain a decorative panel with a 3D textured structure. The topcoat is BMZ-1012-30, with a coating weight of 12g / m². 2 The decorative panel described can be used in furniture.

[0097] The penetrating and reinforcing base Jetgood4281, the filling putty BMZ-303A, the masking white base BMZ-809W, the polyurethane acrylic resin TUN187, the epoxy acrylic resin TUE75, and the topcoat BMZ-1012-30 are all from Bonford New Materials Co., Ltd.

[0098] Example 3

[0099] After polishing, leveling, and dust removal, the calcium silicate board (a type of inorganic board) is coated with a penetrating and reinforcing primer BMZ-5100 at a coverage of 35g / m². 2 After curing, apply two coats of BMZ-303A filler putty, 40g / m² per coat. 2 After each coat is cured, apply two more coats of white base coat BMZ-809W, each coat 22g / m². 2 Each coating is cured after application, and then digital printing is performed using UV ink to obtain a 2D pattern layer on the substrate surface.

[0100] A photocurable coating is applied to the surface of the 2D pattern layer and then pre-cured. The photocurable coating has a thickness of 100 μm and contains, by weight percentage, 41.8% polyurethane acrylate resin TUN208, 25% polyurethane acrylate resin TUN88, 30% reactive diluent dipropylene glycol diacrylate, 0.2% of the first photoinitiator phenyl bis(2,4,6-trimethylbenzoyl)phosphine oxide (with maximum absorption peak wavelengths of 370 nm and 405 nm), and 3% of the second photoinitiator 754 (with maximum absorption peak wavelengths of 255 nm and 325 nm). The pre-curing light source is a UV-LED lamp with a main emission wavelength of 405 nm.

[0101] Then, the texture developer is printed onto the pre-cured surface using an inkjet printer. The texture developer is controlled to align with the desired texture location, i.e., with the corresponding position of the 2D pattern layer. A second curing is performed using a mercury lamp to obtain a cured coating. The texture developer contains, by weight percentage, 10% epoxy acrylate resin TUE21, 60% photoinitiator 1173, and 30% reactive diluent 1,6-hexanediol diacrylate.

[0102] The unhardened parts of the cured coating are then removed by polishing and wire drawing to form a texture. Polishing and wire drawing is done using a polishing and wire drawing machine, which contains 10 sets of steel brushes and 4 sets of nylon brushes. During polishing and wire drawing, the high-hardness steel brushes first draw out a rough texture shape (i.e., the first polishing and wire drawing), and then the low-hardness nylon brushes trim the burrs (i.e., the second polishing and wire drawing) to obtain a more beautiful texture.

[0103] Finally, two coats of BMZ-8240-10 topcoat are applied to obtain a decorative panel with a 3D textured structure. The coating amount for each topcoat is 6g / m².2 Each coat of paint is cured after application. The decorative panels described can be used for interior wall decoration.

[0104] The penetrating and reinforcing base BMZ-5100, the filling putty BMZ-303A, the masking white base BMZ-809W, the polyurethane acrylic resin TUN208 and TUN88, the epoxy acrylic resin TUE21, and the topcoat BMZ-8240-10 are all from Bonfer New Materials Co., Ltd.

[0105] Although the above embodiments have provided a detailed description of this application, they are only some embodiments of this application, not all embodiments. Other embodiments can be obtained based on these embodiments without creative intent, and these embodiments all fall within the protection scope of this application.

Claims

1. A method for producing a decorative material having a 3D texture structure, characterized by, Includes the following steps: The pre-treated substrate is digitally printed to obtain a 2D pattern layer on the substrate surface. A photocurable coating is applied to the surface of the 2D pattern layer and pre-cured. Then, a texture developer is sprayed onto the pre-cured surface for a second curing to obtain a cured coating. The cured coating includes a hardened portion and an unhardened portion; After removing the uncured portions of the hardened coating through polishing and wire drawing, a topcoat is applied to obtain a decorative material with a 3D textured structure.

2. The production method according to claim 1, wherein The pretreatment includes one or more of leveling, filling, attaching, and masking.

3. The production method according to claim 1, wherein The digital printing includes UV ink printing, water-based ink printing, water-based UV ink printing, or solvent-based ink printing.

4. The production method according to claim 1, wherein After obtaining the 2D pattern layer, before applying the light-cured coating, a primer and / or abrasion-resistant coating are applied to the surface of the 2D pattern layer and then cured.

5. The preparation method according to claim 1, characterized in that, The components of the photocurable coating include a photocurable resin and a first photoinitiator; The photocurable resin includes acrylic resin; The acrylic resin includes one or more of polyurethane acrylic resin, epoxy acrylic resin, polyester acrylic resin, polyether acrylic resin, and pure acrylic resin.

6. The production method according to claim 5, wherein The wavelength of the maximum absorption peak of the first photoinitiator is 350–420 nm; The mass of the first photoinitiator is 0.001% to 5% of the mass of the photocurable coating.

7. The production method according to claim 6, wherein The first photoinitiator includes at least one of 2,4,6-trimethylbenzoyl diphenylphosphine oxide, phenyl bis(2,4,6-trimethylbenzoyl)phosphine oxide, (2,4,6-trimethylbenzoyl)bis(p-tolyl)phosphine oxide) and ethyl 2,4,6-trimethylbenzoyl phenylphosphonate.

8. The preparation method according to claim 5, characterized in that, The components of the photocurable coating also include at least one of an active diluent, a coating additive, and a second photoinitiator; The mass of the second photoinitiator is 0.5% to 5% of the mass of the photocurable coating; The wavelength of the maximum absorption peak of the second photoinitiator is 200–350 nm.

9. The preparation method according to claim 8, characterized in that, The second photoinitiator includes at least one of 1-hydroxycyclohexylphenyl ketone, 2-hydroxy-2-methyl-1-phenyl-1-propanone, methyl benzoylformate, oxobis(ethane-2,1-diyl)bis(2-oxo-2-phenylacetic acid ester), benzophenone, 4-chlorobenzophenone, and 4-methylbenzophenone.

10. The preparation method according to claim 1, characterized in that, The preliminary curing is carried out by irradiating the photocurable coating with a preliminary curing light source, wherein the main wavelength of the ultraviolet light generated by the preliminary curing light source is 350-420nm. After initial curing, the thickness of the photocurable coating is 10–300 μm.

11. The preparation method according to claim 1, characterized in that, The texture developer includes a third photoinitiator; The wavelength of the maximum absorption peak of the third photoinitiator is 200–420 nm; The third photoinitiator includes one or more of the following: 2,4,6-trimethylbenzoyl diphenylphosphine oxide, (2,4,6-trimethylbenzoyl)di(p-tolyl)phosphine oxide, ethyl 2,4,6-trimethylbenzoylphenylphosphine, phenylbis(2,4,6-trimethylbenzoyl)phosphine oxide, 1-hydroxycyclohexylphenyl ketone, 2-hydroxy-2-methyl-1-phenyl-1-propanone, methyl benzoylformate, oxo-bis(ethane-2,1-diyl)bis(2-oxo-2-phenylacetic acid), benzophenone, 4-chlorobenzophenone, and 4-methylbenzophenone.

12. The preparation method according to claim 11, characterized in that, The mass percentage of the third photoinitiator in the texture developer is ≥20%.

13. The preparation method according to claim 11, characterized in that, The texture developer also includes at least one of acrylic resin, reactive diluent, and coating additives.

14. The preparation method according to claim 13, characterized in that, The reactive diluent includes 1,6-hexanediol diacrylate; The mass percentage of acrylic resin in the texture developing solution is ≤20%; The reactive diluent in the texture developer contains ≤70% by mass.

15. The preparation method according to claim 1, characterized in that, When using the inkjet printing texture developer, the texture developer is aligned with the pattern and position of the 2D pattern layer.

16. The preparation method according to claim 1, characterized in that, The second curing is a photocuring process in which the texture developer is applied to the coating and then cured by irradiating it with a second curing light source. The light source for the second curing is one or more of gallium lamps, mercury lamps, halogen lamps, and electrodeless lamps.

17. The preparation method according to claim 1, characterized in that, The removal of unhardened portions of the cured coating by polishing and wire drawing is performed using a polishing and wire drawing machine. The polishing and wire drawing machine includes 4 to 10 sets of high-hardness brushes and 2 to 6 sets of low-hardness brushes; the high-hardness brushes are steel brushes, and the low-hardness brushes are nylon brushes or composite brushes, wherein the composite brushes are made of steel and nylon. The polishing and wire drawing process includes sequentially performing a first polishing and wire drawing and a second polishing and wire drawing. The first polishing and wire drawing is performed using the high-hardness brush, and the second polishing and wire drawing is performed using the low-hardness brush.

18. The preparation method according to claim 1, characterized in that, The coating consists of 1 to 3 coats.

19. A decorative material with a 3D texture structure prepared by the preparation method according to any one of claims 1 to 18.

20. The application of the decorative material with a 3D textured structure as described in claim 19 in flooring or decorative panels.

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