Floor tile having transferred glaze coating layer and manufacturing method therefor

Abstract

The present application belongs to the technical field of decorative materials, and specifically relates to a floor tile having a transferred glaze coating layer and a manufacturing method therefor. Provided in the present application is the manufacturing method for the floor tile having the transferred glaze coating layer, comprising the following steps: performing first coating of a glaze coating on a surface of a transfer film, and performing first curing to form a glaze coating layer, so as to obtain a glaze surface transfer film; performing second coating of an adhesive layer on a surface of a pretreated substrate; and applying the glaze surface transfer film to the surface of the adhesive layer, performing second curing, and removing the transfer film, so as to obtain the floor tile having the transferred glaze coating layer. In the present application, first, the transfer film is coated with the glaze coating layer and then is used for preparing a floor tile, wherein the side of the glaze coating layer in contact with the transfer film is isolated from oxygen when undergoing the curing, thereby preventing the affect of oxygen inhibition on polymerization; in addition, wear-resistant particles are concentratedly arranged on one side of the transfer film, and a mirror surface feature of the transfer film results in a mirror coating layer, so that the glaze coating layer has excellent wear resistance and scratch resistance and mirror surface effects.

Description

A floor tile with a transfer glaze coating and its preparation method Technical Field

[0001] This application belongs to the field of decorative materials technology, specifically relating to a floor tile with a transfer glaze coating and its preparation method. Background Technology

[0002] Floor covering materials need to withstand long-term foot traffic, scratches, and friction; therefore, they all have strict requirements for wear resistance and scratch resistance. Among many floor covering materials, ceramic tiles and marble, due to their inorganic composition and unique firing process, have excellent advantages such as waterproofing, corrosion resistance, wear resistance, and easy cleaning, and can also achieve a mirror-like smooth effect. However, ceramic tiles also have some drawbacks that are widely criticized, such as their high density, fragility, difficulty in cutting, high installation and transportation costs, cold and hard feel underfoot, and high production energy consumption.

[0003] Plastic flooring and inorganic boards are inexpensive, environmentally friendly, and easily recyclable, and have gradually become mainstream decorative materials in recent years. These materials require surface coatings to provide wear resistance, scratch resistance, and better decorative effects, but often cannot simultaneously achieve a mirror-like finish and excellent wear and scratch resistance. Related technologies disclose a composite flooring and its preparation method that can achieve a mirror-like finish and excellent wear and scratch resistance. However, this process requires preparing a coating on a polymer film and then bonding it to a substrate, making the process relatively complex and preventing in-line production. Furthermore, the product line involves substrates, coatings, polymer films, and other materials, resulting in high overall costs. Additionally, the composite flooring produced is limited by the polymer film, resulting in low hardness. Summary of the Invention

[0004] In view of this, the purpose of this application is to provide a floor tile with a transfer glaze coating and a method for preparing the same. The floor tile prepared by the method of this application has a smooth glaze surface, good wear resistance and scratch resistance, and high hardness.

[0005] This application provides a method for preparing floor tiles with a transfer glaze coating, comprising the following steps:

[0006] A glaze coating is first applied to the surface of the transfer film, and then cured to form a glaze coating to obtain a glaze transfer film.

[0007] A second adhesive layer is applied to the surface of the pretreated substrate, and the glaze transfer film is then attached to the surface of the adhesive layer. After a second curing, the transfer film is removed to obtain a floor tile with a transfer glaze coating.

[0008] Preferably, the glaze coating comprises the following raw materials in parts by weight: 5-50 parts of wear-resistant particles, 10-80 parts of acrylic resin, 1-5 parts of photoinitiator, 0-50 parts of reactive diluent, and 0.1-5 parts of additives.

[0009] Preferably, the wear-resistant particles have a Mohs hardness ≥ 9;

[0010] The wear-resistant particles include micron-sized particles, which include one or more of alumina, zirconium carbide, silicon carbide, boron carbide, silicon nitride, and diamond micron powder.

[0011] Preferably, the coating amount of the glaze is 3-20 g / m². 2 .

[0012] Preferably, the transfer film includes a polyester film, a polypropylene film, or a polyethylene film.

[0013] Preferably, the thickness of the transfer film is 20–500 μm.

[0014] Preferably, the first curing is radiation curing, and the radiation curing uses a gallium lamp, mercury lamp, UV-LED lamp, halogen lamp or electrodeless lamp.

[0015] Preferably, the pre-processed substrate includes a first pre-processed substrate, a second pre-processed substrate, or a third pre-processed substrate. The first pre-processed substrate includes a first substrate, a first primer layer, a masking white base layer, a pattern layer, and a second primer layer stacked sequentially. The first substrate includes a plastic board, an inorganic board, a wood board, or a composite board.

[0016] The second pre-processed substrate includes a plastic substrate containing a polymer white film, a pattern layer, an adhesive primer layer, and a wear-resistant primer layer stacked sequentially; or it includes a plastic substrate containing a polymer printed film, an adhesive primer layer, and a wear-resistant primer layer stacked sequentially.

[0017] The third pretreatment plate is a composite plastic substrate, which includes a plastic substrate, a printed film, and a transparent film stacked in sequence.

[0018] Preferably, the adhesive layer is a transparent UV coating or a transparent adhesive layer.

[0019] This application also provides floor tiles with a transfer glaze coating obtained by the preparation method described in the above technical solution.

[0020] Compared with the prior art, this application has the following beneficial effects:

[0021] This application provides a method for preparing floor tiles with a transfer glaze coating, comprising the following steps: firstly coating a glaze coating onto the surface of a transfer film, first curing to form a glaze coating, obtaining a glaze transfer film; secondly coating an adhesive layer onto the surface of a pretreated substrate, applying the glaze transfer film to the surface of the adhesive layer, second curing, removing the transfer film, and obtaining floor tiles with a transfer glaze coating. This application first coats the glaze coating onto the transfer film and then transfers it to the floor tile. The side of the glaze coating in contact with the transfer film is oxygen-isolated during curing, without the influence of oxygen inhibition. Wear-resistant particles are concentrated on one side of the transfer film, and the mirror properties of the transfer film create a mirror coating, possessing excellent wear resistance, scratch resistance, and a mirror effect. Furthermore, the preparation method of this application is not limited by the film transfer process, allowing for the coating of a higher hardness onto the pretreated substrate, resulting in floor tiles with high hardness. The floor tiles with a transfer glaze coating obtained by this application have excellent wear resistance and scratch resistance, and have broad application prospects, suitable for garages, flooring, heavy commercial applications, and other fields. Moreover, the preparation method of this application is simple, the energy consumption is much lower than that of ceramic tile production, and it can be used for in-line production on different substrates to produce floor decoration materials with ceramic tile effect. Detailed Implementation

[0022] This application provides a method for preparing floor tiles with a transfer glaze coating, comprising the following steps:

[0023] A glaze coating is first applied to the surface of the transfer film, and then cured to form a glaze coating to obtain a glaze transfer film.

[0024] A second adhesive layer is applied to the surface of the pretreated substrate, and the glaze transfer film is then attached to the surface of the adhesive layer. After a second curing, the transfer film is removed to obtain a floor tile with a transfer glaze coating.

[0025] Unless otherwise specified, all materials and equipment used in this application are commercially available products in the field.

[0026] In this application, a glaze coating is first applied to the surface of the transfer film, and then cured to form a glaze coating to obtain a glaze transfer film.

[0027] In this application, the transfer film preferably includes polyester film (PET), polypropylene film (PP), or polyethylene film (PE). The thickness of the transfer film is preferably 20–500 μm, more preferably 30–200 μm, and specifically can be 70 μm or 100 μm. This application utilizes the mirror-like smoothness of the transfer film to achieve a mirror-like finish after transfer, resulting in a ceramic tile-like effect. The transfer film can be selected with different gloss levels and textures, allowing the transferred glaze coating to achieve varying gloss and texture effects.

[0028] In this application, the glaze coating comprises the following raw materials in parts by weight: 5-50 parts of wear-resistant particles, 10-80 parts of acrylic resin, 1-5 parts of photoinitiator, 0-50 parts of reactive diluent, and 0.1-5 parts of additives.

[0029] In this application, the acrylate resin preferably includes 10-100 wt% of a high-functionality acrylate resin, wherein the functionality of the high-functionality acrylate resin is preferably 2-15, specifically 9, and the high-functionality acrylate resin preferably includes one or more of polyurethane acrylate resin, epoxy acrylate resin and polyester acrylate resin.

[0030] In this application, the Mohs hardness of the wear-resistant particles is preferably ≥9; the wear-resistant particles preferably include micron-sized particles, and the micron-sized particles preferably include one or more of alumina, zirconium carbide, silicon carbide, boron carbide, silicon nitride, boron nitride, and diamond micropowder, specifically a mixture of diamond micropowder, silicon carbide micropowder, and alumina micropowder, with the mass ratio of diamond micropowder, silicon carbide micropowder, and alumina micropowder preferably being 1:1:2. The particle size of the wear-resistant particles is preferably 1–30 μm, more preferably 3–20 μm, specifically 10 μm. The particle size range of the wear-resistant particles ensures both good transparency and a high volume concentration, resulting in a concentrated arrangement of wear-resistant particles on the glaze coating surface after the transfer process, while also achieving a mirror effect.

[0031] In this application, the wear-resistant particles preferably also include nanoparticles, and the mass percentage of the nanoparticles in the glaze coating is preferably 0.5% to 10%, specifically 3%; the nanoparticles preferably include one or more of alumina, zirconium carbide, silicon carbide, boron carbide, silicon nitride, boron nitride, and diamond nanoparticles; the particle size of the nanoparticles is preferably 20 to 300 nm. This application combines nanoparticles and micron-sized particles to give the coating excellent wear resistance.

[0032] In this application, the nanoparticles are preferably used in the form of a nano-hybrid resin; by mass parts, the raw materials of the nano-hybrid resin preferably include 60-90 parts of a photocurable resin, 5-30 parts of nanoparticles and 0.5-10 parts of a silane coupling agent, specifically 82 parts of a photocurable resin, 15 parts of nanoparticles and 3 parts of a silane coupling agent; the photocurable resin is preferably TUE21 epoxy acrylate resin from Bonford New Materials Co., Ltd., the nanoparticles are preferably Aladdin wear-resistant alumina with a particle size of 50 nm, and the silane coupling agent is preferably Dow Corning 6011.

[0033] In this application, the photoinitiator is preferably photoinitiator 184 (1-hydroxycyclohexylphenyl ketone) or photoinitiator 1173 (2-hydroxy-2-methyl-1-phenyl-1-propanone).

[0034] In this application, the reactive diluent is preferably DPGDA (dipropylene glycol diacrylate).

[0035] In this application, the additives preferably include one or more of dispersants, defoamers, and antisettling agents. The dispersant is preferably BASF EFKA-AFCONA-4010, the defoamer is preferably TEGOAirex 920, and the antisettling agent is preferably fumed silica, which is preferably Degussa R974.

[0036] In this application, the glaze coating preferably comprises the following raw materials in parts by weight: 15 parts wear-resistant particles, 55 parts acrylic resin, 3 parts photoinitiator, 26 parts reactive diluent, and 1 part additive, wherein the additive includes 0.4 parts dispersant, 0.2 parts defoamer, and 0.4 parts anti-settling agent; or comprises the following raw materials in parts by weight: 20 parts wear-resistant particles, 37 parts acrylic resin, 20 parts nano-hybrid resin, 2 parts photoinitiator, 20 parts reactive diluent, and 1 part additive, wherein the additive includes 0.4 parts dispersant, 0.2 parts defoamer, and 0.4 parts anti-settling agent.

[0037] In this application, the coating amount of the glaze is preferably 3-20 g / m². 2 More preferably 5-15 g / m 2 Specifically, it can be 8g / m 2 .

[0038] In this application, the process preferably includes applying a release agent to the surface of the transfer film before the first coating. This application does not have specific requirements regarding the type or amount of the release agent; any agent commonly used by those skilled in the art can be used. The release agent facilitates the subsequent peeling of the transfer film.

[0039] This application does not have any special requirements for the method of the first coating; any method commonly used by those skilled in the art can be adopted.

[0040] In this application, the first curing is preferably radiation curing, and the radiation curing is preferably performed using a gallium lamp, mercury lamp, UV-LED lamp, halogen lamp, or electrodeless lamp. The side of the glaze coating in contact with the transfer film is isolated from oxygen during curing, thus avoiding the influence of oxygen inhibition on polymerization. This greatly increases the crosslinking density, and wear-resistant particles are concentrated on one side of the transfer film, becoming the glaze coating of the floor tile after transfer. This coating possesses excellent wear and scratch resistance, while the mirror-like properties of the transfer film create a mirror-like coating.

[0041] In this application, after the first curing to form the glaze coating, it is preferable to further apply a second adhesive layer to the surface of the glaze coating.

[0042] After obtaining the glaze transfer film, this application applies a second adhesive layer to the surface of the pretreated substrate, applies the glaze transfer film to the surface of the adhesive layer, cures it for the second time, removes the transfer film, and obtains a floor tile containing a transfer glaze coating.

[0043] In this application, the pre-processed substrate includes a first pre-processed substrate, a second pre-processed substrate, or a third pre-processed substrate. The first pre-processed substrate includes a first substrate, a first primer layer, a masking white base layer, a pattern layer, and a second primer layer stacked sequentially. The first substrate includes a plastic board, an inorganic board, a wood board, or a composite board.

[0044] The plastic board preferably includes PVC board, PET board, PETG board or PP board, and the PVC board preferably includes SPC board or WPC board; the inorganic board preferably includes calcium silicate board, magnesium phosphate board, magnesium oxide board, flammable wood board or cement fiber board; the wood board preferably includes solid wood board or multi-layer solid wood composite board;

[0045] The primer of the first primer layer preferably includes an adhesion primer or a penetrating primer; when the first substrate is a plastic board or wood board with good surface strength, the surface of the first substrate is preferably coated with an adhesion primer; when the first substrate is an inorganic board with poor surface strength and high porosity, the surface of the first substrate is preferably coated with a penetrating primer to strengthen the surface. The penetrating primer is preferably a dual-curing penetrating primer. The dual-curing penetrating primer preferably has the characteristics of UV curing and isocyanate-hydroxy addition polymerization reaction. UV coatings have the advantages of fast curing speed and high-speed continuous production, but UV coatings cannot be used after penetrating into the pores of the substrate. Two-component polyurethane coatings have the reaction characteristics of isocyanate-hydroxy addition polymerization reaction, and have excellent properties such as waterproof, impact resistance, and wear resistance. However, they require high-temperature baking or long-term curing to achieve cross-linking reaction, resulting in low production efficiency. The dual-curing penetrating primer has the characteristics of deep penetration, continuous production, and excellent surface modification and strengthening effect on the substrate.

[0046] The pattern layer is preferably obtained by digital printing, and the ink used for digital printing preferably includes UV ink, water-based ink, or solvent-based ink.

[0047] The primer for the second primer layer is preferably a wear-resistant primer; the wear-resistant primer is preferably a high-hardness wear-resistant primer, and the wear-resistant primer preferably includes 5-60% inorganic powder by weight, wherein the inorganic powder preferably has a Mohs hardness ≥6 and a particle size preferably 3-100 μm; the inorganic powder preferably includes one or more of glass powder, silica powder, quartz powder, alumina, zirconium carbide, silicon carbide, boron carbide, silicon nitride, boron nitride, and diamond, more preferably alumina. The coating amount of the wear-resistant primer is preferably 10-200 g / m². 2 More preferably 20–150 g / m 2 .

[0048] The first primer layer, the white base coat, the pattern layer, and the second primer layer are preferably applied independently in at least one coat, specifically one or two coats, with each coat preferably having a coverage of 5–150 g / m². 2 Specifically, it can be 10g / m 2 20g / m 2 25g / m 2 40g / m 2 Or 80g / m 2 After each coating, curing is preferably performed, preferably by gallium lamp curing or mercury lamp curing.

[0049] Preferably, a filler putty layer is also included between the first primer layer and the white masking layer; preferably, an adhesive primer layer is also included between the white masking layer and the pattern layer to ensure good bonding between the coatings.

[0050] The second pre-processed substrate preferably comprises a plastic substrate containing a polymer white film, a pattern layer, an adhesion primer layer, and a wear-resistant primer layer stacked sequentially; or it comprises a plastic substrate containing a polymer printed film, an adhesion primer layer, and a wear-resistant primer layer stacked sequentially. One side of the polymer white film on the plastic substrate containing the polymer white film is in contact with the pattern layer.

[0051] The third pretreatment plate is preferably a composite plastic substrate, which preferably comprises a plastic substrate, a printed film, and a transparent film stacked sequentially. The plastic substrate is preferably an SPC substrate. A glaze coating is transferred to one side of the transparent film. Preferably, an adhesion primer and a wear-resistant primer are also provided on the transparent film to ensure good adhesion and wear and scratch resistance of the coating.

[0052] In this application, the adhesive layer is preferably a transparent UV coating or a transparent adhesive layer. The raw materials for the transparent UV coating preferably include: 10–80 wt% of a high-Tg monomer, wherein the high-Tg monomer has a Tg ≥ 40°C; and / or 10–80 wt% of an acrylic resin, wherein the acrylic resin has a functionality ≥ 2, and the acrylic resin includes one or more of polyurethane acrylic resin, polyester acrylic resin, and epoxy acrylic resin. The transparent adhesive layer is preferably a transparent PUR adhesive or a transparent two-component polyurethane adhesive.

[0053] In this application, when the glaze transfer film is applied to the surface of the adhesive layer, the non-carrier film side of the glaze transfer film is in contact with the adhesive layer on the surface of the pretreated substrate, that is, the glaze coating is in contact with the adhesive layer on the surface of the pretreated substrate, or the second adhesive layer on the surface of the glaze coating is in contact with the adhesive layer on the surface of the pretreated substrate.

[0054] In this application, the second curing process preferably includes one or more of gallium lamps, mercury lamps, UV-LED lamps, halogen lamps, electrodeless lamps, and EB curing.

[0055] In this application, the removal of the transfer film preferably further includes a third curing of the glaze coating, wherein the third curing preferably includes one or more of gallium lamp, mercury lamp, UV-LED lamp, halogen lamp, electrodeless lamp and EB curing.

[0056] In this application, the removal of the coating film preferably further includes: coating the back of the floor tile, slicing it, and creating tenons; the coating treatment preferably uses a UV back coating to achieve the purpose of aesthetics, waterproofing, and balancing the shrinkage of the front coating.

[0057] The method for preparing floor tiles with transfer glaze coating provided in this application is simple and can be used to produce floor decoration materials with high hardness, excellent wear and scratch resistance and mirror effect in an online production line, thereby achieving the purpose of replacing ceramic tiles.

[0058] This application also provides floor tiles with a transfer glaze coating obtained by the preparation method described in the above technical solution.

[0059] The floor tiles with transfer glaze coating obtained in this application can achieve the effect of ceramic tiles. When applied to PVC flooring, especially SPC or WPC boards, they can combine the high-end mirror effect, stain resistance, wear resistance, and scratch resistance of ceramic tiles with the advantages of PVC flooring, such as easy cutting, easy installation and transportation, and comfortable feel underfoot. They do not have the defects of ceramic tiles, such as fragility, high transportation and installation costs, and a hard feel underfoot, nor the defects of PVC flooring, such as poor wear and scratch resistance. When applied to inorganic boards, they can also achieve the effect of replacing ceramic tiles, and have the advantages of being lightweight and inexpensive compared to ceramic tiles.

[0060] The preparation method of this application only requires one production line. After filling and leveling the substrate and making the pattern, the glaze coating is transferred and the finished product is obtained directly in the production line, which is simpler.

[0061] To further illustrate this application, the following detailed description of the floor tiles with transfer glaze coating and their preparation method provided in this application is provided in conjunction with embodiments, but these should not be construed as limiting the scope of protection of this application.

[0062] Example 1

[0063] A type of floor tile with a transfer glaze coating is prepared as follows:

[0064] 1. After polishing and leveling the calcium silicate board, apply a penetrating primer BMZ-5100 with a coating thickness of 40g / m². 2 Gallium lamp curing is used; then two coats of BMZ-3016 filler putty are applied, each coat 25g / m². 2 Each coat is cured with a mercury lamp; then two coats of white base coat BMZ-824WH are applied, each coat 20g / m². 2 Each coating layer is cured with a gallium lamp; then, a pattern layer is created through digital printing, followed by the application of a primer BMZ-855 with a coating thickness of 10 g / m². 2 The process involves curing with a mercury lamp, followed by application of a wear-resistant primer BMZ-323C with a coating thickness of 80 g / m². 2 The substrate was cured using a mercury lamp to obtain a pretreated substrate.

[0065] The digital printing uses LUS-210 UV ink from Shenzhen Xinghe Lianhui Digital Technology Co., Ltd. BMZ-5100, BMZ-3016, BMZ-824WH, BMZ-855, and BMZ-323C are all from Bonfer New Materials Co., Ltd., and the wear-resistant primer BMZ-323C contains 30wt% alumina (40μm particle size, from Zhengzhou Yuechi Abrasives Co., Ltd.)

[0066] 2. Transfer the glaze coating onto the pre-treated substrate. The steps for transferring the glaze coating are as follows: apply a UV wear-resistant coating to the transfer film and perform a first radiation curing using a gallium lamp. Then, apply an adhesive layer to the pre-treated substrate without curing it. Place the transfer film coated with the UV wear-resistant coating and cured onto the adhesive layer, ensuring the UV wear-resistant coating is in contact with the adhesive layer. Perform a second radiation curing using a gallium lamp. Then, remove the transfer film and perform a third radiation curing using a gallium lamp to form a glaze coating with excellent wear and scratch resistance, thus obtaining the coated floor tile.

[0067] The transfer film is a 70μm thick PET film from Anhui Aokai Materials Co., Ltd. The UV abrasion-resistant coating has a thickness of 8g / m². 2The raw materials (by weight) for preparing the UV wear-resistant coating include 15 parts wear-resistant particles, 55 parts acrylate resin, 3 parts photoinitiator, 26 parts reactive diluent, and 1 part additives. The wear-resistant particles are 10μm diamond micropowder from Henan Bolai Rong Superhard Materials Co., Ltd. The acrylate resin is a 9-functional polyurethane acrylate, model TUN142, from Bonfer New Materials Co., Ltd. The photoinitiator is 184 (1-hydroxycyclohexylphenyl ketone), and the reactive diluent is DPGDA (dipropylene glycol diacrylate). The additives include 0.4 parts dispersant, 0.2 parts defoamer, and 0.4 parts anti-settling agent. The dispersant is BASF EFKA-AFCONA-4010, the defoamer is TEGOAirex 920, and the anti-settling agent is fumed silica, specifically Degussa R974.

[0068] The adhesive layer is a high-hardness transparent UV coating, comprising, by weight percentage: 40% DPGDA (dipropylene glycol diacrylate) (Tg 104℃), 40% hexafunctional polyurethane acrylate, 3% photoinitiator, and 17% difunctional polyurethane acrylate. The hexafunctional polyurethane acrylate is TUN153 from Bonfer New Materials Co., Ltd., the photoinitiator includes 1% TPO and 2% 184, and the difunctional polyurethane acrylate is TUN102 from Bonfer New Materials Co., Ltd.

[0069] A coating is applied to the back of the coated floor tiles to achieve both aesthetic appeal and waterproofing. BMZ-820 from Bonfer New Materials Co., Ltd. is used, with a coating thickness of 30g / m². 2 The tiles are cured with mercury lamps, then divided into sections and grooved to obtain floor tiles with a transfer glaze coating.

[0070] Example 2

[0071] A type of floor tile with a transfer glaze coating is prepared as follows:

[0072] 1. After polishing and leveling the SPC substrate, apply a primer BPVC-1335 with a coating thickness of 10g / m². 2 Curing is performed using a mercury lamp; then two coats of white base coat BMZ-824WH are applied, each coat 20g / m². 2 Each coating layer is cured with a gallium lamp; then, a pattern layer is created through digital printing, followed by the application of a primer BMZ-855 with a coating thickness of 10 g / m². 2 The process involves curing with a mercury lamp, followed by application of a wear-resistant primer BMZ-323C with a coating thickness of 80 g / m². 2 The substrate was cured using a mercury lamp to obtain a pretreated substrate.

[0073] BPVC-1335 is from Bonfer New Materials Co., Ltd.

[0074] 2. The steps and raw materials for transferring the glaze coating are the same as in Example 1.

[0075] A coating treatment is applied to the back of the coated floor tiles to balance the shrinkage of the front coating. BPVC-1625-15 from Bonfer New Materials Co., Ltd. is used, with a coating thickness of 50g / m². 2 The tiles are cured with mercury lamps, then divided into sections and grooved to obtain floor tiles with a transfer glaze coating.

[0076] Example 3

[0077] A type of floor tile with a transfer glaze coating is prepared as follows:

[0078] 1. A pattern layer is digitally printed on one side of the PVC white film on an SPC substrate containing PVC white film, and then an adhesive primer BPVC-1335 is applied with a coating thickness of 10g / m². 2 Mercury lamp curing is used, followed by application of wear-resistant primer BMZ-323C with a coating thickness of 80g / m². 2 The substrate was cured using a mercury lamp to obtain a pretreated substrate.

[0079] The method for preparing SPC substrates containing PVC white film involves online lamination of the PVC white film while the SPC substrate is being extruded, and this method comes from Zhejiang Yongyu Home Furnishings Co., Ltd.

[0080] 2. The steps and raw materials for transferring the glaze coating are the same as in Example 1.

[0081] A coating treatment is applied to the back of the coated floor tiles to balance the shrinkage of the front coating. BPVC-1625-15 from Bonfer New Materials Co., Ltd. is used, with a coating thickness of 50g / m². 2 The tiles are cured with mercury lamps, then divided into sections and grooved to obtain floor tiles with a transfer glaze coating.

[0082] Example 4

[0083] A type of floor tile with a transfer glaze coating is prepared as follows:

[0084] 1. Apply a primer BPVC-1335 to an SPC substrate containing PVC printed film, with a coating thickness of 10 g / m. 2 Mercury lamp curing is used, followed by application of wear-resistant primer BMZ-323C with a coating thickness of 80g / m². 2 The substrate was cured using a mercury lamp to obtain a pretreated substrate.

[0085] The method for preparing SPC substrates containing PVC printed film involves online lamination of the PVC printed film while the SPC substrate is being extruded, and this method comes from Zhejiang Yongyu Home Furnishings Co., Ltd.

[0086] 2. The steps and raw materials for transferring the glaze coating are the same as in Example 1.

[0087] A coating treatment is applied to the back of the coated floor tiles to balance the shrinkage of the front coating. BPVC-1625-15 from Bonfer New Materials Co., Ltd. is used, with a coating thickness of 50g / m². 2 The tiles are cured with mercury lamps, then divided into sections and grooved to obtain floor tiles with a transfer glaze coating.

[0088] Example 5

[0089] A type of floor tile with a transfer glaze coating is prepared as follows:

[0090] 1. Apply a primer BPVC-1335 to the transparent film side of a composite substrate containing sequentially stacked SPC substrate, PVC printed film, and PVC transparent film, with a coating thickness of 10 g / m. 2 The process involves curing with a mercury lamp, followed by application of a wear-resistant primer BMZ-323C with a coating thickness of 80 g / m². 2 The substrate was cured using a mercury lamp to obtain a pretreated substrate.

[0091] The composite substrate is prepared by simultaneously extruding an SPC substrate and laminating an online PVC printed film and a PVC transparent film, according to Zhejiang Yongyu Home Furnishings Co., Ltd.

[0092] 2. The steps and raw materials for transferring the glaze coating are the same as in Example 1.

[0093] A coating treatment is applied to the back of the coated floor tiles to balance the shrinkage of the front coating. BPVC-1625-15 from Bonfer New Materials Co., Ltd. is used, with a coating thickness of 50g / m². 2 The tiles are cured with mercury lamps, then divided into sections and grooved to obtain floor tiles with a transfer glaze coating.

[0094] Example 6

[0095] A type of floor tile with a transfer glaze coating is prepared as follows:

[0096] 1. Apply a primer BPVC-1335 to the transparent film side of a composite substrate containing sequentially stacked SPC substrate, PVC printed film, and PVC transparent film, with a coating thickness of 10 g / m. 2 The substrate was cured using a mercury lamp to obtain a pretreated substrate.

[0097] The composite substrate is prepared by simultaneously extruding an SPC substrate and laminating an online PVC printed film and a PVC transparent film, according to Zhejiang Yongyu Home Furnishings Co., Ltd.

[0098] 2. The steps and raw materials for transferring the glaze coating are the same as in Example 1.

[0099] The coated floor tiles are then divided into sections and tenons are cut to obtain floor tiles with a transfer glaze coating.

[0100] Example 7

[0101] A type of floor tile with a transfer glaze coating is prepared as follows:

[0102] 1. After polishing and leveling the PET substrate, apply an adhesion primer BPT-2101A with a coating thickness of 10g / m². 2 Curing is performed using a mercury lamp; then two coats of white base coat BMZ-824WH are applied, each coat 20g / m². 2 Each coating layer is cured with a gallium lamp; then, a pattern layer is created through digital printing, followed by the application of a primer BMZ-855 with a coating thickness of 10 g / m². 2 The process involves curing with a mercury lamp, followed by application of a wear-resistant primer BMZ-323C with a coating thickness of 80 g / m². 2 The substrate was cured using a mercury lamp to obtain a pretreated substrate.

[0103] BPT-2101A is from Bonfer New Materials Co., Ltd.

[0104] 2. The steps and raw materials for transferring the glaze coating are the same as in Example 1.

[0105] The coated floor tiles are then divided into sections and tenons are cut to obtain floor tiles with a transfer glaze coating.

[0106] Example 8

[0107] A type of floor tile with a transfer glaze coating is prepared as follows:

[0108] 1. After polishing and leveling the SPC substrate, apply a primer BPVC-1335 with a coating thickness of 10g / m². 2 Curing is performed using a mercury lamp; then two coats of white base coat BMZ-824WH are applied, each coat 20g / m². 2 Each coating layer is cured with a gallium lamp; then, a pattern layer is created through digital printing, followed by the application of a primer BMZ-855 with a coating thickness of 10 g / m². 2 The process involves curing with a mercury lamp, followed by application of a wear-resistant primer BMZ-323C with a coating thickness of 80 g / m². 2 The substrate was cured using a mercury lamp to obtain a pretreated substrate.

[0109] 2. Transfer the glaze coating onto the pre-treated substrate. The steps for transferring the glaze coating are as follows: apply a UV wear-resistant coating to the transfer film and perform a first radiation curing using a gallium lamp. Then, apply an adhesive layer to the pre-treated substrate without curing it. Place the transfer film coated with the UV wear-resistant coating and cured onto the adhesive layer, ensuring the UV wear-resistant coating is in contact with the adhesive layer. Perform a second radiation curing using a gallium lamp. Then, remove the transfer film and perform a third radiation curing using a gallium lamp to form a glaze coating with excellent wear and scratch resistance, thus obtaining the coated floor tile.

[0110] The transfer film is a 100μm thick PET film from Anhui Aokai Materials Co., Ltd. The UV abrasion-resistant coating has a thickness of 15g / m². 2 The raw materials (by weight) for preparing the UV wear-resistant coating include 20 parts wear-resistant particles, 37 parts acrylate resin, 20 parts nano-hybrid resin, 2 parts photoinitiator, 20 parts reactive diluent, and 1 part additive. The wear-resistant particles include 5 parts diamond micropowder, 5 parts silicon carbide micropowder, and 10 parts alumina micropowder, all with a particle size of 10 μm. The acrylate resin is a 9-functional polyurethane acrylate, model TUN142, sourced from Bonfer New Materials Co., Ltd. The photoinitiator is 1173 (2-hydroxy-2-methyl-1-phenyl-1-propanone), and the reactive diluent is DPGDA (dipropylene glycol diacrylate). The additives include 0.4 parts of dispersant, 0.2 parts of defoamer, and 0.4 parts of anti-settling agent. The dispersant is BASF EFKA-AFCONA-4010, the defoamer is TEGOAirex 920, and the anti-settling agent is fumed silica, specifically Degussa R974. The nano-hybrid resin is obtained by dispersing and coating nanoparticles with a silane coupling agent using a photocurable resin. By weight, the nano-hybrid resin contains 82 parts of photocurable resin, 15 parts of nanoparticles, and 3 parts of silane coupling agent. The photocurable resin is TUE21 epoxy acrylate resin from Bonford New Materials Co., Ltd., the nanoparticles are Aladdin wear-resistant alumina with a particle size of 50 nm, and the silane coupling agent is Dow Corning 6011. The adhesive layer is the same as in Example 1.

[0111] A coating treatment is applied to the back of the coated floor tiles to balance the shrinkage of the front coating. BPVC-1625-15 from Bonfer New Materials Co., Ltd. is used, with a coating thickness of 50g / m². 2 The tiles are cured with mercury lamps, then divided into sections and grooved to obtain floor tiles with a transfer glaze coating.

[0112] Comparative Example 1

[0113] The composite flooring is prepared using the method described in Chinese Patent CN 117230957 A, "A Composite Flooring and Its Preparation Method." After coating a transparent film or a polymer composite film containing a printed film with a radiation-cured coating and a glaze layer, the composite flooring is adhered to a substrate using an adhesive. The preparation method is as follows:

[0114] A PVC composite film is obtained by thermally bonding a PVC printed film and a PVC transparent film. A UV abrasion-resistant coating is applied to the printed film, followed by a first radiation curing process using a gallium lamp. A primer, BPVC-1335, with a coating thickness of 10 g / m² is then applied to the transparent film of the PVC composite film. 2 The process involves curing with a mercury lamp, followed by applying an adhesive layer without curing. A transfer film coated with a cured UV abrasion-resistant coating is then applied to the adhesive layer, ensuring the UV abrasion-resistant coating is in contact with the adhesive layer. A second radiation curing is performed using a gallium lamp. The transfer film is then removed, and a third radiation curing is performed using a gallium lamp to obtain a colored functional film. The PVC transparent film, with a thickness of 300 μm, is sourced from Foshan Tianan Plastics Co., Ltd.; the PVC printed film, with a thickness of 100 μm, is sourced from Hangzhou Lin'an Ginkgo Decoration Materials Co., Ltd. The thickness and raw materials of the transfer film and UV abrasion-resistant coating are the same as in Example 1.

[0115] The obtained colored functional film was applied to a leveled SPC substrate using PUR adhesive to prepare a composite floor.

[0116] Comparative Example 2

[0117] A certain commercially available ceramic tile

[0118] Performance testing

[0119] (1) Hardness: The hardness of the floor decoration material was obtained by referring to the test examples and comparative examples of GB / T 6739-2022 standard. The higher the test data, the higher the hardness.

[0120] (2) Impact resistance: The impact resistance of the floor decoration materials was tested according to the examples and comparative examples in GB / T 17657-2013 standard.

[0121] (3) Abrasion resistance: The abrasion resistance of the floor decoration material was obtained by referring to the test examples and comparative examples of GB / T 1768-2006 standard. The test conditions were: 500g load, P180 sandpaper, and abrasion value after 100 revolutions. The smaller the abrasion value, the better the abrasion resistance.

[0122] (4) Repeated traffic scratch resistance: The repeated traffic scratch resistance of the floor covering materials obtained by the test examples and comparative examples were tested according to the additional test method HSP1305MM of EN 16094-2021. The evaluation level is from C1 to C5, from good to poor.

[0123] The test results are shown in Table 1:

[0124] Table 1. Performance test results of the floor decoration materials obtained in the examples and comparative examples.

[0125] In Example 1, the substrate of the floor tile is calcium silicate board, which, like ceramic tile, is an inorganic material and is easily broken. However, calcium silicate board has a lower density than ceramic tile, making it easier to transport and install, and this process consumes less energy. The composite flooring prepared by the method in Comparative Example 1 contains a PVC composite film in the middle. The PVC composite film has low hardness, and due to the limitations of the film transfer process, it cannot be coated with a higher hardness coating, resulting in a composite flooring with low hardness. Repeatable traffic scratch testing was used to evaluate the flooring's scratch resistance under harsh conditions, specifically evaluating its scratch resistance under a certain load of high-hardness or sharp materials. As shown in Table 1, the floor tiles with transferred glaze coating prepared using the method of this application achieve a mirror-like ceramic tile surface effect while exhibiting superior scratch resistance and wear resistance comparable to ceramic tiles. Moreover, compared to the process in Comparative Example 1 where a glaze coating is prepared on the composite film material and then bonded, the floor tiles of this application have lower costs, reducing the cost of the film material and processes, and possess higher hardness, with performance closer to that of ceramic tiles.

[0126] Although the above embodiments have provided a detailed description of this application, they are only some embodiments of this application, not all embodiments. People can obtain other embodiments based on the embodiments of this application without creative effort, and these embodiments all fall within the protection scope of this application.

Claims

1. A method for preparing floor tiles containing a transfer glaze coating, characterized in that, Includes the following steps: A glaze coating is first applied to the surface of the transfer film, and then cured to form a glaze coating to obtain a glaze transfer film. A second adhesive layer is applied to the surface of the pretreated substrate, and the glaze transfer film is then attached to the surface of the adhesive layer. After a second curing, the transfer film is removed to obtain a floor tile with a transfer glaze coating.

2. The preparation method according to claim 1, characterized in that, The glaze coating comprises the following raw materials in parts by weight: 5-50 parts of wear-resistant particles, 10-80 parts of acrylic resin, 1-5 parts of photoinitiator, 0-50 parts of reactive diluent, and 0.1-5 parts of additives.

3. The preparation method according to claim 2, characterized in that, The wear-resistant particles have a Mohs hardness ≥ 9; The wear-resistant particles include micron-sized particles, which include one or more of alumina, zirconium carbide, silicon carbide, boron carbide, silicon nitride, and diamond micron powder.

4. The preparation method according to claim 3, characterized in that, The wear-resistant particles also include nanoparticles, and the mass percentage of the nanoparticles in the glaze coating is 0.5% to 10%.

5. The preparation method according to claim 4, characterized in that, The nanoparticles are used in the form of a nano-hybrid resin; by mass, the raw materials of the nano-hybrid resin include 60-90 parts of a photocurable resin, 5-30 parts of nanoparticles and 0.5-10 parts of a silane coupling agent.

6. The preparation method according to claim 2 or 3, characterized in that, The coating amount of the glaze is 3-20 g / m². 2 .

7. The preparation method according to claim 1, characterized in that, The transfer film includes a polyester film, a polypropylene film, or a polyethylene film.

8. The preparation method according to claim 1 or 7, characterized in that, The thickness of the transfer membrane is 20–500 μm.

9. The preparation method according to claim 2, characterized in that, The first curing is radiation curing, which uses gallium lamps, mercury lamps, UV-LED lamps, halogen lamps, or electrodeless lamps.

10. The preparation method according to claim 1, characterized in that, The pre-processed substrate includes a first pre-processed substrate, a second pre-processed substrate, or a third pre-processed substrate. The first pre-processed substrate includes a first substrate, a first primer layer, a masking white base layer, a pattern layer, and a second primer layer stacked sequentially. The first substrate includes a plastic board, an inorganic board, a wood board, or a composite board. The second pre-processed substrate includes a plastic substrate containing a polymer white film, a pattern layer, an adhesive primer layer, and a wear-resistant primer layer stacked sequentially; or it includes a plastic substrate containing a polymer printed film, an adhesive primer layer, and a wear-resistant primer layer stacked sequentially. The third pretreatment plate is a composite plastic substrate, which includes a plastic substrate, a printed film, and a transparent film stacked in sequence.

11. The preparation method according to claim 10, characterized in that, The plastic board in the first substrate includes PVC board, PET board, PETG board or PP board; the inorganic board includes calcium silicate board, magnesium phosphate board, magnesium oxide board, phenolic resin board or cement fiber board.

12. The preparation method according to claim 1, characterized in that, The adhesive layer is a transparent UV coating or a transparent adhesive layer.

13. Floor tiles with a transfer glaze coating obtained by the preparation method according to any one of claims 1 to 12.

Images