CN107813575A - 一种装饰板材或片材、制备方法及其设备 - Google Patents

一种装饰板材或片材、制备方法及其设备 Download PDF

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Publication number
CN107813575A
CN107813575A CN201711274511.2A CN201711274511A CN107813575A CN 107813575 A CN107813575 A CN 107813575A CN 201711274511 A CN201711274511 A CN 201711274511A CN 107813575 A CN107813575 A CN 107813575A
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sheet material
solid film
dalle
film
base material
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张书龙
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DONGGUAN NANYU RESIN HARDWARE Co Ltd
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DONGGUAN NANYU RESIN HARDWARE Co Ltd
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Priority to CN201711274511.2A priority Critical patent/CN107813575A/zh
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Abstract

本发明涉及一种装饰板材或片材、其制备方法及设备。所述装饰板材或片材包括基材、固体胶片以及位于基材及固体胶片之间的粘结层，所述固体胶片通过粘结层紧密地粘结于所述基材表面，从而形成光亮、平滑、透明的外观镜面效果，并且固体的环保胶片不会释放有害物，因此所制得的装饰板材或片材对人体健康无毒害，而且外表美观，耐磨、耐刮、耐剥离、耐水洗、耐候、耐腐蚀等各项性能都非常优良。

Description

一种装饰板材或片材、制备方法及其设备
技术领域
本发明涉及建筑装饰材料及其制备领域，尤其是指一种装饰板材或片材、制备方法及其设备。
背景技术
为营造舒适温馨的室内环境，当前室内装修工程中，人们会大量使用各种装饰板材或片材，例如PVC板，硅酸钙板、木板、胶合板、密度板、集成板、铝塑板、铝板。片材如：陶瓷地砖、大理石等。这些单调的板材或片材往往要进行美化，在表面形成图案。为了保护这些图案达到表面耐磨、耐刮、耐剥离、耐水洗、耐候、耐腐蚀的目的，通常在图案表面涂覆一层胶水并固化后形成保护膜胶面。然而，在固化过程中，胶水从液体向固体转化时由于收缩、挥发、固化不完全等原因而使保护膜表面产生密集的、明显的不规则纹路；同时，产生的气泡消散后形成圆圈状痕迹；另外也会因为杂质混入而影响外观；再者，所用胶水在固化过程中很难固化完全，导致日后在使用过程中未反应的原料迁移挥发而释放出有害物污染环境影响用户身体健康。
发明内容
本发明所要解决的技术问题是：提供一种装饰板材或片材，以克服现有装饰板材或片材表面外观瑕疵、表层性能差、以及存在环保隐患并影响用户健康等问题。
本发明所要解决的另一技术问题是：提供一种制备装饰板材或片材的方法，以克服现有方法制备的装饰板材或片材表面外观瑕疵、表层性能差、以及存在环保隐患并影响用户健康等问题。
本发明所要解决的再一技术问题是：提供一种制备装饰板材或片材的设备，以制备一种装饰板材或片材改善表面外观及性能以及解决环保隐患等问题。
为解决前述技术问题，本发明采用如下技术方案：一种装饰板材或片材，包括基材、固体胶片以及位于基材及固体胶片之间的粘结层，所述固体胶片通过粘结层紧密地粘结于所述基材表面。
所述基材是建筑装饰板材或片材的原料板材或片材；所述粘结层是由粘结剂固化后形成；所述固体胶片包括一张、一卷或一块整体的塑胶片材。所述固体胶片通过粘结剂紧密地粘结于基材表面形成光亮、平滑的镜面；所述固体胶片为不会释放有害物的环保胶片，是一种耐磨、耐刮、耐剥离、耐水洗、耐候、耐腐蚀的塑胶片材。
所述基材包括PVC板，硅酸钙板、木板、胶合板、密度板、集成板、铝塑板、铝板、陶瓷地砖、大理石板中的一种或几种形成的板状或片状基材；所述基材上表面形成图案或花纹；所述固体胶片是热塑性塑胶片材。
所述固体胶片为透明塑胶片材；所述固体胶片厚度为0.01-0.35mm；所述固体胶片是热塑性塑胶原料一次成型的整体片材。
所述UV树脂为聚氨酯丙烯酸酯、环氧丙烯酸酯、聚酯丙烯酸酯、纯丙烯酸酯中的一种或几种；所述光引发剂为：裂解型光引发剂、夺氢型光引发剂、阳离子光引发剂、大分子光引发剂、水基光引发剂中的一种或几种；粘结剂中UV树脂的重量份为5~85；粘结剂中光引发剂的重量份为1~10。
所述粘结层为透明粘结层；所述固体胶片是PET、PP、PE、PVC、PC、APET、PMMA、PS塑胶片材中的一种或几种制成。
本发明还提供一种制备装饰板材或片材的方法，包括以下步骤：
步骤一，提供装饰板材或片材的原料板材或片材作为基材以及提供固体胶片；
步骤二，在基材表面上胶，具体是在基材表面均匀涂覆一层粘结剂；
步骤三，粘结固体胶片：在粘结剂表面紧密地压合固体胶片；
步骤四：固化粘结剂，在装饰板材或片材的表面整体形成固体胶片保护膜。
所述步骤一进一步包括表面处理和/或形成图案或花纹的步骤；所述步骤一的固体胶片是由热塑性塑胶原料预先成型为整体的薄片。所述步骤三中，固体胶片和基材用转印机的胶辊紧密地压合在一起；所述胶辊压力为1PSI~500PSI。
本发明还提供一种用于制备装饰板材或片材的设备，包括输送基材的传动装置、连续传送固体胶片的传动装置、上下各一对分别承接传动装置输送的胶片以及基材并在两对胶辊之间压合胶片及基材的转动胶辊；所述设备进一步包括设置于两对胶辊后方、对压合的基材和胶片之间的粘结剂进行光照固化的紫外线光源。
本发明的有益效果是：本发明采用整体固体胶片，通过较强的粘结剂粘结于基材表面，从而形成光亮、平滑、具有镜面效果的环保装饰板材或片材，其外表美观，且耐磨性、耐刮性、耐候性、耐水性、耐腐蚀性都非常优良。进一步地，固体的环保胶片不会释放有害物质，因此所制得的装饰板材或片材对人体无毒害。
本发明的制备方法工艺简单，利于批量生产，产品质量远超过目前现有的技术方法所生产出来的市场产品，并且价廉物美。
本发明的使用的设备结构简单，可一次性完成胶片的粘结，生产效率高，产品外观及性能良好。
下面结合附图对本发明作进一步的详细描述。
附图说明
图1是本发明实施例的装饰板材或片材基板的结构示意图。
图2是本发明实施例的装饰板材或片材制备过程示意图。
图3是本发明实施例的装饰板材或片材的结构示意图。
具体实施方式
下面结合附图和具体实施例对本发明作进一步详细说明。发明所提供的附图及下述实施例的描述并非将发明限制在这些实施例中，而是提供给本领域普通技术人员来制造和使用本发明。需要说明的是，在不冲突的情况下，本申请中的各实施例及实施例中的特征可以相互结合。
如图1-2所示的本发明的一种装饰板材或片材10，包括基材1，固体胶片3以及粘结层2，所述固体胶片3通过粘结层2平整牢固地粘合于基材1表层。
所述基材1是建筑装饰板材或片材的原料板材或片材，包括但不限于PVC板，硅酸钙板、木板、胶合板、密度板、集成板、铝塑板、铝板、陶瓷地砖、大理石板等。为更好的装饰效果，所述基材1上可通过印刷、打印(如3D打印）、喷涂、转印、电镀、电泳、雕刻、粘贴、复膜、电镀等工艺在所述基材1表面形成图案或花纹11。所述基材1在形成图案11和/或粘结固体胶片3之前先进行表面处理，包括但不限于清洁、除尘、除静电、打磨、等离子处理等，以提高表面性能，利于提高图案的附着力以及利于粘结固体胶片3。基材1可以为整块、整张或整卷原料板材或片材。
所述粘结层2对于固体胶片3以及基材1之间有极强的粘结力，是由粘结剂固化后形成。作为一种实施方式，所述粘结剂是添加有光引发剂的UV树脂形成的UV胶。
在一些实施方式中，所述UV树脂为聚氨酯丙烯酸酯、环氧丙烯酸酯、聚酯丙烯酸酯、纯丙烯酸酯中的一种或几种，重量份为5~85。所述光引发剂为：裂解型光引发剂、夺氢型光引发剂、阳离子光引发剂、大分子光引发剂、水基光引发剂中的一种或几种，重量份为1~10。
作为一些实施方式，粘结剂中进一步添加有功能单体，根据具体需要进行选择，例如单官能基单体、双官能基单体、三官能基单体、多官能基单体中的一种或几种，重量份为5~85。例如粘结剂中添加重量份为5~85的辛基-癸基丙烯酸酯功能单体，以获得与胶片3的粘结性强、颜色浅且耐黄变性好的UV胶。
作为一种实施方式举例，使用UV光固化粘接剂，其由UV树脂、光引发剂及辛基-癸基丙烯酸酯单体组成，配方重量比为：
UV树脂 45
光引发剂 4
辛基-癸基丙烯酸酯 51
UV树脂为聚氨酯丙烯酸树酯，光引发剂为1-羟基环己基苯基甲酮。
可以理解，现有技术的粘结剂首先能满足对固体胶片3与基材1之间的较强粘结力，防止固体胶片3剥离便可适用；进一步地根据产品的需要选择例如无毒害、透明、耐黄化性等特点的粘结剂。例如，选用粘结剂为东莞市南昱树脂五金制品有限公司的UV61，UV62。
所述粘结层较佳地为透明粘结层，紧密地将固体胶片3粘结于基材1表面，而且不影响基材1表面图案或花纹的展示。因此，粘结层2所用粘结剂对固体胶片具有良好的粘结性、颜色浅、透明度好、耐黄变性好。
作为一种实施方式，所述粘结层2在固化前经过辊压，从而压实、去除多余的粘结剂，且同时去除气泡等，以便于获得的装饰板材或片材不会存在不规则纹路、气泡痕、杂质等外观不佳的瑕疵以及反应不完全的问题。
固体胶片3包括一张、一卷或一块整体的塑胶片材或薄片，可以是单一的塑胶薄片，还可进一步以塑胶薄片为载体设置其它附加功能层，例如图案层、加固层等而形成的片材。作为一种实施方式，所述固体胶片3是一次成型的整体塑胶片材，包括但不限于PET、PP、PE、PVC、PC、APET、PMMA、PS等塑胶原料一次成型的整体塑胶片材。
固体胶片3通过粘结剂紧密地粘结于基材表面形成光亮、平滑的镜面；其为不会释放有害物的环保胶片，是一种耐磨、耐刮、耐剥离、耐水洗、耐候、耐腐蚀的塑胶片材。在一些实施例中，固体胶片3是热塑性塑胶片材。
较佳地固体胶片3为透明胶片，相应地具有良好的透明度，以利于展示基材1表面图案或花纹。
作为一种实施方式，本发明采用的固体胶片3是由塑胶原料例如经挤出或压延一次成型的固体环保胶片，不会释放毒害物质，所以对人体健康无害，整体结构的机械及物理性能优良。
作为一种实施方式，固体胶片3是整卷或整张的薄片，由胶辊（如图3）传送并辊压至基材1表面进行粘结的。在一些实施例中，固体胶片3厚度为0.01-0.35mm。
所述装饰板材或片材10是在粘结固体胶片3并固化后按需要切割成成品。单个成品结构与整张、整块或整卷装饰板材或片材10的结构相同，只是大小不同。本发明中装饰板材或片材包括整卷（张或块）或单个成品。
进一步参照图3，本发明实施例还提供一种制备装饰板材或片材10的方法，包括以下步骤：
步骤一，提供前述装饰板材或片材的原料板材或片材作为基材，并提供前述固体胶片；
步骤二，在基材表面上胶：在基材表面均匀涂覆一层粘结剂；
步骤三，粘结固体胶片：在粘结剂表面紧密地压合固体胶片；
步骤四：固化，在装饰板材或片材的表面整体形成胶片保护膜，表面光亮平滑。
对于整片或整卷的基材和/或固体胶片，前述方法进一步包括：
步骤五：切割形成成品。
所述步骤一进一步包括表面处理和/或形成图案或花纹的步骤，例如，步骤一进一步包括：
1）对基材进行表面处理，包括但不限于表面打磨（例如80-600＃砂打磨）、等离子处理等，以提高基材表面的附着力；
2）清洁除尘、除静电处理，以防尘；
3）制作图案和/或花纹，例如在基材表面上胶，并以转印的方式将印有图案的膜转印于基材表面，从而形成转印的图案层。
所述步骤二，在前述图案层表面或基材表层涂覆前述粘结剂。
可采用辊涂、淋涂、喷涂等现有技术的方法在基材表面涂覆粘结剂层。
所述步骤三中，将固定胶片3，例如透明胶片（PET、PE、PP、PVC、PC等）和基材1用转印机的胶辊4紧密地压合在一起。在基材1与胶片3的粘合过程中，调节好压合胶辊的平压力，一般可根据产品在1PSI~500PSI之间的压力范围进行调节。调节好的胶片3与基材1紧密地压合在一起，多余的粘结剂和气泡随着基材1和胶片3而自动流出基材1的边缘。利用图3所示的设备可一步完成固体胶片3附着到基材1上的工艺步骤。
所述步骤四中，是使用紫外光进行固化成型，再经切割形成单位成品。从而在装饰板材或片材的表面整体形成胶片保护膜，其表面光亮平滑，具有良好的耐磨性、耐水性（表面胶片为整体无间隙）、耐候性，内部的图案或花纹均一且无气泡或杂质，外观完美。
完成上述制备方法所使用的设备包括：连续输送基材1的传动装置6例如带轮，连续传送胶片3的传动装置5例如转动轴，上下各一对转动胶辊4，分别承接传动装置5、6输送的胶片3以及基材1，并在两对胶辊4之间压合。其中基材1表面可以是已涂覆有粘结剂，也可以在基材1的传送上方设置喷涂装置7，在基材1被送入一对转动胶辊4之前进行涂覆粘结剂。
进一步地，所述制备设备中包括紫外线光源8，设置于两对胶辊后方，对压合的基材1和胶片3之间的粘结剂进行光照固化。
这里列举的例子和附图所示，仅作为示范说明但并不作为限定，本发明可实现的具体实施例。由此可利用或派生其他实施例，以便于在不脱离本发明揭露的范围内可进行结构和逻辑替换及改变。仅为方便起见，本发明保护主题的这些实施例单独地或共同指作“本发明”，但如果不止一个发明被披露时，并不主观地限定本申请的范围为任何单一发明或发明概念。因此，尽管在此揭露了具体实施例，但仍然可以由获得相同目的的任何方案替代所示的具体实施例。本说明书意图涵盖各种实施例的任何和所有的适应性或变换方式。前述实施例的组合，以及其他未特别说明的实施例，本领域技术人员基于前述说明书的描述是显而易见的。
尽管已经示出和描述了本发明的实施例，对于本领域的普通技术人员而言，可以理解在不脱离本发明的原理和精神的情况下可以对这些实施例进行多种变化、修改、替换和变型，本发明的保护范围由所附权利要求及其等同范围限定。

Claims (10)

1.一种装饰板材或片材，包括基材；其特征在于：所述装饰板材或片材进一步包括固体胶片以及位于基材及固体胶片之间的粘结层，所述固体胶片通过粘结层紧密地粘结于所述基材表面。
2.如权利要求1所述的装饰板材或片材，其特征在于：所述基材是建筑装饰板材或片材的原料板材或片材；所述粘结层是由粘结剂固化后形成；所述固体胶片包括一张、一卷或一块整体的塑胶片材。
3.如权利要求2所述的装饰板材或片材，其特征在于：所述固体胶片通过粘结剂紧密地粘结于基材表面形成光亮、平滑的镜面；所述固体胶片为不会释放有害物的环保胶片，是一种耐磨、耐刮、耐剥离、耐水洗、耐候、耐腐蚀的塑胶片材。
4.如权利要求2所述的装饰板材或片材，其特征在于：所述基材包括PVC板，硅酸钙板、木板、胶合板、密度板、集成板、铝塑板、铝板、陶瓷地砖、大理石板中的一种或几种形成的板状或片状基材；所述基材上表面形成图案或花纹；所述固体胶片是热塑性塑胶片材。
5.如权利要求3所述的装饰板材或片材，其特征在于：所述固体胶片为透明塑胶片材；所述固体胶片厚度为0.01-0.35mm；所述固体胶片是热塑性塑胶原料一次成型的整体片材。
6.如权利要求2所述的装饰板材或片材，其特征在于：所述粘结剂是添加有光引发剂的UV树脂；所述UV树脂为聚氨酯丙烯酸酯、环氧丙烯酸酯、聚酯丙烯酸酯、纯丙烯酸酯中的一种或几种；所述光引发剂为：裂解型光引发剂、夺氢型光引发剂、阳离子光引发剂、大分子光引发剂、水基光引发剂中的一种或几种；粘结剂中UV树脂的重量份为5~85；粘结剂中光引发剂的重量份为1~10。
7.如权利要求2所述的装饰板材或片材，其特征在于：所述粘结层为透明粘结层；所述固体胶片是PET、PP、PE、PVC、PC、APET、PMMA、PS塑胶片材中的一种或几种制成。
8.一种制备如权利要求1~7中任一项所述装饰板材或片材的方法，其特征在于：所述方法包括以下步骤：
步骤一，提供装饰板材或片材的原料板材或片材作为基材以及提供固体胶片；
步骤二，在基材表面上胶：在基材表面均匀涂覆一层粘结剂；
步骤三，粘结固体胶片：在粘结剂表面紧密地压合固体胶片；
步骤四：固化粘结剂，在装饰板材或片材的表面整体形成固体胶片保护膜。
9.如权利要求8所述的方法，其特征在于：所述步骤一进一步包括表面处理和/或形成图案或花纹的步骤；所述步骤一的固体胶片是由热塑性塑胶原料预先成型为整体的薄片；所述步骤三中，固体胶片和基材用转印机的胶辊紧密地压合在一起；所述胶辊压力为1PSI~500PSI。
10.一种用于制备如权利要求1~7中任一项所述装饰板材或片材的设备，其特征在于：所述设备包括输送基材的传动装置、连续传送固体胶片的传动装置、上下各一对分别承接传动装置输送的胶片以及基材并在两对胶辊之间压合胶片及基材的转动胶辊；所述设备进一步包括设置于两对胶辊后方、对压合的基材和胶片之间的粘结剂进行光照固化的紫外线光源。
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