CN113829699A - 一种新型复合板材及其加工工艺 - Google Patents
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Abstract
本发明公开了一种新型复合板材及其加工工艺，所述板材包括基材层，包括基材层，所述基材层上设有对其进行防护的表面结构层，所述表面结构层通过中间粘接层粘接在基材层上，所述表面结构层背离基材层的一侧设有在外侧承受压力并传递至表面结构层一侧、连同表面结构层形成3D触感造型的3D触感层，该板材产生通过在3D触感层上压纹产生，不进行UV及光固化处理，不需要化学腐蚀，不需要电镀，工艺及产品更加环保；该新型复合板材表面设置有表面结构层和可选择的表层保护层，对板材外侧进行柔性保护，满足常规的折弯、适当拉伸、冲剪、弯曲等机械加工，应用更加广泛，本发明结构简单、实用性强、易于使用和推广。
Description
技术领域
本发明具体涉及板材技术领域，具体是一种新型复合板材及其加工工艺。
背景技术
在传统的家电用板或装饰板领域，为了提升装饰效果，常采用带3D触感的金属板材，这种板材的现有工艺为预先制造UV压纹或拉丝处理的PET膜，然后将成品PET膜贴合到卷料或片状金属表面，得到所需的带3D触感金属板材。这种制作方法虽然广为使用，但其工艺和产品在实际的使用中却存在如下需改进之处：
1、工艺复杂，PET表面UV处理工艺要求高，制作难度大，如控制不佳，易产生UV脱落或不耐刮问题，严重影响产品的质量；
2、工艺成本高，UV涂层需在UV灯光固化，通常固化过程还需要添加惰性气体保护，UV灯寿命短需要经常更换，UV材料及工艺成本高；
3、工艺不环保，UV固化过程，有较多的化学溶剂挥发，随加工的进行造成的污染环境；
4、成型加工性弱，UV固化后的PET聚酯膜明显变脆，易撕裂，在180折弯成型时容易脆裂。
基于此，需要一种新型的新型复合板材。
发明内容
本发明的目的在于提供一种新型复合板材，以解决上述背景技术中提出的问题。
为实现上述目的，本发明提供如下技术方案：
一种新型复合板材，包括基材层，所述基材层上表面设有对其进行防护的表面结构层，所述表面结构层通过中间粘接层粘接在基材层上，所述表面结构层背离基材层的上表面设有通过辊压或雕刻形成带凹凸3D触感效果的3D触感层。
更进一步的方案：所述基材层为金属底板。
更进一步的方案：所述表面结构层的下表面设有印制的颜色或图案的中间效果层。
更进一步的方案：所述表面结构层的下表面的中间效果层还添加有形成不同颜色效果或图案或金属闪烁的金属粉沫。
更进一步的方案：所述3D触感层采用聚对苯二甲酸乙二醇酯、双向拉伸聚丙烯薄膜、亚克力膜或聚氯乙烯膜中的一种。
更进一步的方案：所述3D触感层的上表面还设有对板材表面进行柔性保护的表层保护层。
更进一步的方案：所述表层保护层为PE保护膜、牛皮纸、PET等聚酯保护膜中的一种。
更进一步的方案：所述基材层的下表面还设有提高板材防锈蚀能力的背面保护层。
更进一步的方案：所述背面保护层包括一层或多层环氧类或聚酯类涂层。
本申请的另一个目的在于，提出一种包含上述新型复合板材的加工工艺，其包括以下步骤：
1、在表面结构层下表面，通过印刷技术或喷绘技术，在表面结构层的下方印制需要的颜色或图案，形成不同颜色效果或图案的中间效果层；
2、通过涂布工艺或多层共挤吹塑成膜，将带有热熔粘接性能的中间粘接层粘接于表面结构层、中间效果层的下方，形成组合膜状物；
3、将组合膜状物贴合到基材层上表面，在基材层的下表面辊涂一层或多层环氧类或聚酯类涂层，达到装饰或防腐性能，或通过在聚酯膜表面流延淋涂热熔粘接层贴覆于基材层的下表面；
4、通过辊压或雕刻工艺对组合膜状物的作用，在表面结构层上方表面辊压或雕刻出需要的纹理、图案等3D触感层，形成精细化的美观的3D表面触感；
5、根据需要在3D触感层的外侧面粘接表面保护层；
6、根据需要在基材层的背面粘接背面保护层。
与现有技术相比，本发明的有益效果是：该板材产生通过在3D触感层2上压纹产生，不进行UV及光固化处理，不需要化学腐蚀，不需要电镀，工艺及产品更加环保；该新型复合板材表面设置有3D触感层和可选择的表层保护层，二者相互配合，对板材外侧进行柔性保护，满足常规的折弯、适当拉伸、冲剪、弯曲等机械加工，应用更加广泛；同时可卷料连续化生产，对比传统蚀刻板效果更高，能耗更低，本发明结构简单、实用性强、易于使用和推广。
附图说明
图1为新型复合板材的多层结构示意图。
图2为新型复合板材无需表面保护层的示意图。
图3为新型复合板材无需背面保护层的示意图。
图中：表面保护层1、3D触感层2、表面结构层3、中间效果层4、中间粘接层5、基材层6、背面保护层7。
具体实施方式
下面将结合本发明实施例中的附图，对本发明实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例仅仅是本发明一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例，都属于本发明保护的范围。
实施例1
请参阅图1，本发明实施例中，一种新型复合板材，包括基材层6，所述基材层6上表面设有对基材层进行防护的表面结构层3，所述表面结构层3通过中间粘接层5粘接在基材层6上，所述表面结构层3背离基材层6的上表面设有通过辊压或雕刻形成带凹凸3D触感效果的3D触感层2。
所述基材层6可采用不锈钢板、不锈铁板、铝板、铝合金板、镀锡板、冷轧板、镀锌板、镀铬板等，为新型复合板材提供可靠、稳定的金属底层。
所述表面结构层3可采用印刷技术或喷绘技术，在表面结构层3的下方形成需要的颜色或图案的中间效果层4，还可以在中间效果层4中添加金属粉沫，形成不同颜色效果或图案或金属闪烁的效果。
所述表面结构层3采用广泛应用于家具、装饰材料、包装等的聚对苯二甲酸乙二醇酯(PET)、双向拉伸聚丙烯薄膜(BOPP)、亚克力(PMMA)膜或聚氯乙烯膜中的一种，通过3D触感层2在基材层6外形成必要的隔绝保护，使氧气、水蒸气极难渗透穿过，显著的提升板材的防腐性能。
所述的中间粘接层5采用带有热熔粘接性能的高分子材料，通过多层共挤吹塑成膜状粘接于中间粘接层的下方。也可通过辊涂工艺或喷涂工艺将聚氨酯类胶水辊涂或喷涂于基材层6上。
所述3D触感层2是在上述各层结合好后，再在3D触感层2的上表面通过辊压或雕刻出需要的带凹凸的3D触感的效果，辊压的效果同时向3D触感层2下方的表面结构层3、中间效果层4、中间粘接层5和基材层6传递，起到对3D触感层2上的3D造型多层立体化的作用，有利于维持3D触感层2上造型的长久使用，同时采用对3D触感层2上表面的辊压或雕刻操作不仅不需要采用化学腐蚀或电镀等手段，且工艺成本低，产品也更加环保。
实施例2
如图1和图2所示，本实施例与实施例1的基础上，进一步提升新型复合板材的表面保护性能，具体的：
所述3D触感层2的上表面还设有表层保护层1，所述表层保护层1可为PE保护膜(即聚乙烯类保护膜)、牛皮纸、PET等聚酯保护膜等能起到保护表面效果层，根据具体使用的使用需求，选择的在3D触感层2添加表层保护层1，利用表层保护层1给板材提供最外侧的柔性保护。
实施例3
如图1和图3所示，本实施例与实施例1的基础上，进一步提升新型复合板材的安装防锈性能，具体的：
所述基材层6的下表面还设有背面保护层7，所述的背面保护层7可采用辊涂工艺于基材层6的表面辊涂一层或多层环氧类或聚酯类涂层，达到装饰或防腐性能；
所述背面保护层7也可通过在聚酯膜表面流延淋涂热熔粘接层贴覆于基材层6的表面，形成提升产品的装饰扩展及防腐及隔热性能；还可额外的通过粘接一层由PE保护膜、牛皮纸、PET等聚酯保护膜，保护产品背面，
在基材板6的防锈能力不足或安装环境易锈蚀时，通过背面保护层7进行必要的防护，在基材板6具有一定防锈能力时，且使用环境干燥、不易腐蚀时，可以取消背面保护层7。
实施例4
本实施例提出一种包含上述新型复合板材的加工工艺，其包括以下步骤：
1、在表面结构层3下表面，通过印刷技术或喷绘技术，在表面结构层3的下方印制需要的颜色或图案，形成不同颜色效果或图案的中间效果层4；
2、通过涂布工艺或多层共挤吹塑成膜，将带有热熔粘接性能的中间粘接层5粘接于表面结构层3、中间效果层4的下方，形成组合膜状物；
3、将组合膜状物贴合到基材层6上表面，在基材层6的下表面辊涂一层或多层环氧类或聚酯类涂层，达到装饰或防腐性能，或通过在聚酯膜表面流延淋涂热熔粘接层贴覆于基材层6的下表面；
4、通过辊压或雕刻工艺对组合膜状物的作用，在表面结构层3上方表面辊压或雕刻出需要的纹理、图案等3D触感层2，形成精细化的美观的3D表面触感；
5、根据需要在3D触感层2的外侧面粘接表面保护层1；
6、根据需要在基材层6的背面粘接背面保护层7；
在具体的板材使用时，该板材产生通过在3D触感层2上压纹产生，不进行UV及光固化处理，不需要化学腐蚀，不需要电镀，工艺及产品更加环保；该新型复合板材表面设置有表面结构层3和可选择的表层保护层1，二者相互配合，对板材外侧进行柔性保护，满足常规的折弯、适当拉伸、冲剪、弯曲等机械加工，应用更加广泛，可用于家电用板或装饰板等领域；同时可卷料连续化生产，对比传统蚀刻板效果更高，能耗更低。
对于本领域技术人员而言，显然本发明不限于上述示范性实施例的细节，而且在不背离本发明的精神或基本特征的情况下，能够以其他的具体形式实现本发明。因此，无论从哪一点来看，均应将实施例看作是示范性的，而且是非限制性的，本发明的范围由所附权利要求而不是上述说明限定，因此旨在将落在权利要求的等同要件的含义和范围内的所有变化囊括在本发明内。不应将权利要求中的任何附图标记视为限制所涉及的权利要求。
此外，应当理解，虽然本说明书按照实施方式加以描述，但并非每个实施方式仅包含一个独立的技术方案，说明书的这种叙述方式仅仅是为清楚起见，本领域技术人员应当将说明书作为一个整体，各实施例中的技术方案也可以经适当组合，形成本领域技术人员可以理解的其他实施方式。
Claims (9)
1.一种新型复合板材，包括基材层(6)，其特征在于，所述基材层(6)上表面设有对其进行防护的表面结构层(3)，所述表面结构层(3)通过中间粘接层(5)粘接在基材层(6)上，所述表面结构层(3)背离基材层(6)的上表面设有通过辊压或雕刻形成带凹凸3D触感效果的3D触感层(2)。
2.根据权利要求1所述的新型复合板材，其特征在于，所述基材层(6)为金属底板。
3.根据权利要求1所述的新型复合板材，其特征在于，所述表面结构层(3)的下表面设有印制的颜色或图案的中间效果层(4)。
4.根据权利要求3所述的新型复合板材，其特征在于，所述表面结构层(3)的下表面的中间效果层(4)上还添加有形成不同颜色效果或图案或金属闪烁的金属粉沫。
5.根据权利要求3或权利要求4所述的新型复合板材，其特征在于，所述表面结构层(3)采用聚对苯二甲酸乙二醇酯、双向拉伸聚丙烯薄膜、亚克力膜或聚氯乙烯膜中的一种。
6.根据权利要求1所述的新型复合板材，其特征在于，所述3D触感层(2)的上表面还设有对板材表面进行柔性保护的表层保护层(1)。
7.根据权利要求7所述的新型复合板材，其特征在于，所述表层保护层(1)为PE保护膜、牛皮纸、PET聚酯保护膜中的一种。
8.根据权利要求1所述的新型复合板材，其特征在于，所述基材层(6)的下表面还设有提高板材防锈蚀能力的背面保护层(7)。
9.一种包括权利要求1-8任一所述的新型复合板材的加工工艺，其特征在于，包括以下步骤：
1)、在表面结构层(3)下表面，通过印刷技术或喷绘技术，在表面结构层(3)的下方印制需要的颜色或图案，形成不同颜色效果或图案的中间效果层(4)；
2)、通过涂布工艺或多层共挤吹塑成膜，将带有热熔粘接性能的中间粘接层(5)粘接于表面结构层(3)、中间效果层(4)的下方，形成组合膜状物；
3)、将组合膜状物贴合到基材层(6)上表面，在基材层(6)的下表面辊涂一层或多层环氧类或聚酯类涂层，达到装饰或防腐性能，或通过在聚酯膜表面流延淋涂热熔粘接层贴覆于基材层(6)的下表面；
4)、通过辊压或雕刻工艺对组合膜状物的作用，在表面结构层(3)上方表面辊压或雕刻出需要的纹理、图案3D触感层(2)，形成3D表面触感；
5)、根据需要在3D触感层(2)的外侧面粘接表面保护层(1)；
6)、根据需要在基材层(6)的背面粘接背面保护层(7)。
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