3D Wood-Textured SPC Flooring Bonding Against Warping
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Solution Overview
Problem
SPC flooring with 3D wood texture is prone to warping, deformation, peeling, and detachment due to differences in shrinkage rates between the three-dimensional wood texture layer and the SPC substrate layer, leading to poor decorative effects and reduced service life.
Innovation Solution
A method involving surface treatment of the SPC substrate layer with a base color layer, including steps of extrusion, pore formation, high-energy beam stimulation, primer coating, and sequential application of color paint, pattern, and topcoat layers to enhance adhesion and reduce warping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a three-dimensional wood texture layer is applied on the SPC substrate layer, then the decorative effect and visual impact are improved, but the flooring becomes prone to warping, deformation, and peeling due to shrinkage rate differences
Solution Approach 1:
The patent applies preliminary actions by performing surface treatment (sandblasting or flame treatment) on the SPC substrate layer before applying the wood texture layer. This preliminary surface modification creates anchoring structures that prevent subsequent warping and peeling, addressing the bonding stability issue before the decorative layer is applied.
Solution Approach 2:
The patent introduces a primer layer as an intermediary between the SPC substrate layer and the three-dimensional wood texture layer. This primer layer acts as a mediator that improves adhesion and reduces the negative effects of shrinkage rate differences, preventing peeling and detachment while maintaining the decorative effect.
2Reliability
If the SPC substrate layer excessively absorbs moisture, then the flooring becomes cost-effective and durable, but it causes tile-like arching and edge warping
Solution Approach 1:
The patent applies local quality by creating an uneven surface structure on the SPC substrate layer through sandblasting or flame treatment. This localized surface modification creates areas with different moisture absorption characteristics, allowing the substrate to maintain overall durability while reducing excessive uniform moisture absorption that causes warping.
Solution Approach 2:
The patent changes the physical and chemical parameters of the SPC substrate layer surface through treatment processes. The surface treatment modifies surface energy, roughness, and porosity parameters, which alter moisture absorption characteristics to prevent excessive absorption while maintaining durability.
3Manufacturing precision
If multiple coating layers are applied to achieve 3D wood texture, then the decorative realism is improved, but the production process complexity and internal stress increase
Solution Approach 1:
The patent segments the coating system into distinct functional layers: a base SPC substrate layer, a primer layer for adhesion, and a three-dimensional wood texture layer for decoration. This segmentation allows each layer to perform its specific function optimally while simplifying the overall production process compared to applying multiple decorative coatings.
Solution Approach 2:
The primer layer serves as an intermediary that simplifies the production process by providing a universal bonding interface. This single primer layer replaces the need for multiple adhesive applications or complex surface preparation steps, reducing production complexity while enabling the application of the 3D texture layer.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Stabilizes the bonding between the SPC substrate and three-dimensional wood texture layer, reducing warping and peeling, enhancing decorative effects, and improving product quality.
Implementation Method 1
subjecting the surface of the base color layer obtained in the previous step to high-energy beam stimulation
Implementation Method 2
subjecting the surface of the base color layer obtained in the previous step to high-energy beam stimulation
Implementation Method 3
coating at least a portion of the surface of the base color layer obtained in the previous step with a primer, and curing the primer to obtain a primer layer
Data Source
AI summary
The present invention pertains to the technical field of wood flooring manufacturing, specifically relating to a stone-plastic composite (SPC) flooring with 3D wood grain texture and a method for preparing the same. The invention enhances the surface roughness of the base color layer by imparting irregularly distributed pores on the surface of the base color layer above the SPC substrate. Simultaneously, the paint of the three-dimensional wood grain layer above the base color layer penetrates into and downward through these pores, thereby enhancing the adhesion between the SPC substrate layer and the three-dimensional wood grain layer above it, resulting in more stable bonding. By subjecting the surface of the base color layer to high-energy beam stimulation treatment, its surface roughness is increased. Additionally, the surface molecules of the base color layer are oxidized, generating polar groups with strong polarity, which increases its surface energy and facilitates bonding with the paint of the printed three-dimensional wood grain layer, effectively improving the wettability and adhesion of the base color layer surface. This further effectively reduces the warpage of the three-dimensional wood grain layer, enhances the decorative effect of the three-dimensional wood grain layer, and ensures the product quality of the stone-plastic flooring.