CN115851159A - Composite surface layer structure for wallboard and preparation method - Google Patents

Abstract

The composite surface layer structure and preparation method used for wallboards of the present invention, the composite surface layer structure comprises from top to bottom a wear-resistant paper layer impregnated with melamine, a PVC color film layer, an LVT hard layer, a PVC connection layer, an impregnated The balance paper layer and the perforated EVA or IXPE layer of melamine glue, the wear-resistant paper layer and the balance paper layer are paved with the glued surface of the color film layer and the PVC connection layer respectively, and are connected by high-temperature and high-pressure fusion after the pavement is completed. . The present invention is compounded at one time through high-temperature hot pressing. This type of hard LVT formula system does not have plasticizers such as DOTP and soybean oil, and is more environmentally friendly. Glue EVA or IXPE combined with pore structure to fill structural glue to fit on the wall. The construction technology and installation method are relatively mature. The product is light in weight, smooth in surface, not easy to deform, clear in color, scratch-resistant, stain-resistant, and easy to maintain. cleaning.

Description

Composite surface layer structure for wallboard and preparation method thereof

Technical Field

The invention belongs to the technical field of board materials, and in particular relates to a composite surface layer structure for wall panels and a preparation method thereof.

Background Art

With the development of the construction industry, the interior decoration industry has gradually gained attention. As the top priority of interior decoration, wall panels have gradually become the primary concern of consumers. At present, wall panels are mainly coated or hot-pressed. The coated type mainly refers to integrated wall panels represented by WPC/SPC/bamboo fiber/inorganic cement fiberboard, etc., which use PUR to cover or flatten PVC, PP, PET colored films on the base surface. The process is mature and the process is simple. However, since most of the surfaces use UV coating as a protective layer, the surface scratch resistance is poor. It is easy to cause surface scratches and appearance defects during production, installation and use. In addition, due to the ultraviolet curing process used in the UV process, the color film will turn yellow and discolor at high temperature, and will also age and deform after long-term use. Hot-pressed forming type: this type of wall panels are mostly formed by high-temperature and high-pressure lamination of melamine paper on density boards, fiberboards, multi-layer boards, etc. The base materials of this type of products mostly use phenolic and urea-formaldehyde adhesives as adhesives, and there are problems such as excessive formaldehyde in the production process and the end product. In addition, due to the use of melamine colored paper and balance paper on the surface and bottom layers of the base material, it will also indirectly cause an increase in volatile organic compounds. Therefore, for the above-mentioned traditional wall panel surfaces, there are problems such as the surface is not scratch-resistant, poor scratch performance, easy to turn yellow and discolor after long-term use, a strong plastic feel on the surface, low-end, poor impact resistance, and not environmentally friendly.

Summary of the invention

In view of the problems existing in the prior art, the present invention is designed to provide a composite surface layer structure for wall panels and a preparation method thereof.

The present invention is achieved through the following technical solutions:

A composite surface layer structure for wall panels, which includes, from top to bottom, a wear-resistant paper layer impregnated with melamine, a PVC color film layer, an LVT hard layer, a PVC connecting layer, a balancing paper layer impregnated with melamine glue, and a perforated EVA or IXPE layer. The wear-resistant paper layer and the balancing paper layer are paved with the glued surfaces of the color film layer and the PVC connecting layer respectively, and are melt-connected by high temperature and high pressure after paving.

Furthermore, the thickness of the wear-resistant paper layer is 0.05-0.5 mm; the thickness of the PVC color film layer and the PVC connecting layer are both 0.03-0.1 mm, the thickness of the LVT hard layer is 1-10 mm, and the thickness of the balance paper layer is 0.05-0.5 mm.

Furthermore, the colored layer of the color film layer and any one side of the PVC connecting layer are coated with water-based polyurethane glue, and the coating amount is 5-30g/㎡.

A method for preparing a composite surface layer structure for a wallboard comprises the following steps:

1) The base paper of the wear-resistant layer and the balance paper layer is impregnated with melamine glue and then cured through a drying oven. The amount of impregnation is 20-300g/㎡;

2) Apply water-based polyurethane adhesive on one side of the PVC color film layer and any side of the PVC connection layer, and then cure them in a drying oven. The coating amount is 5-30g/㎡;

3) Add the materials in the proportion of 30-100 parts of polyvinyl chloride, 100-300 parts of calcium carbonate, 1-10 parts of lubricant, 1-15 parts of stabilizer, 2-10 parts of toughening agent, and 2-10 parts of reinforcing agent, first perform hot mixing and then cold mixing, extrude the mixed powder using a twin-screw extruder, and make a hard LVT layer by calendering to determine thickness, cooling, and cutting;

4) Lay steel plate, canvas, bright film, matte film, melamine impregnated wear-resistant paper layer, color film layer, LVT hard layer, PVC connecting layer, melamine impregnated balance paper layer, bright film, matte film, embossed template, and canvas on the tray of the hot and cold integrated or split press from bottom to top, and send them into the press for hot pressing and compounding to obtain a semi-finished composite surface layer;

5) Place the semi-finished product on the conveyor belt with the back side facing up, and evenly roll on 30-50g/m2 polyurethane AB glue, with the ratio of the main agent to the curing agent being 4:1 or 5:1. Then spread EVA or IXPE on the adhesive surface, roll it with a soft rubber roller to exhaust the air, and stack them one by one. After curing for 24 hours, proceed with subsequent processing;

6) Cut the bonded semi-finished products into pieces according to the specified specifications, and perform chamfering and painting.

Furthermore, in step 3), the hot mixing temperature is 100-150°C, the time is 30-60 minutes, and the cold mixing temperature is less than 50°C.

Furthermore, in step 4), during the laying process, the color surface of the color film layer faces the wear-resistant layer, the hot pressing temperature of the hot pressing composite is 110-140°C, the hot machine is divided into three pressure sections of 6-13Mpa, and the hot machine time corresponding to each pressure section is 10-25min, and the cold machine is also divided into three pressure sections of 9-15MPa, and the cold machine time corresponding to each pressure section is 10-15min.

The present invention mainly adopts a melamine-impregnated wear-resistant paper layer, a PVC color film layer, an LVT hard layer, a PVC connecting layer, and a melamine-impregnated balancing paper layer, which are composited in one step by high-temperature hot pressing. This type of hard LVT formula system does not contain plasticizers such as DOTP and soybean oil, and is more environmentally friendly. At the same time, the installation method of this type of product adopts a more common gluing method, using EVA or IXPE with glue combined with a porous structure filled with structural glue to adhere to the wall. The construction process and installation method are relatively mature. The product is light in weight, has a flat surface, is not easy to deform, has clear color, is scratch-resistant, stain-resistant, and easy to maintain and clean.

BRIEF DESCRIPTION OF THE DRAWINGS

Fig. 1 is a diagram of the layered structure of the present invention.

DETAILED DESCRIPTION

The present invention is further described below in conjunction with the accompanying drawings in order to better understand the technical solution.

As shown in Fig. 1, the composite surface layer structure of the wallboard of the present invention is composed of six layers from top to bottom, namely, a wear-resistant paper layer 1, a color film layer 2, an LVT hard layer 3, a PVC connecting layer 4, a balancing paper layer 5, a backing tape adhesive, and a perforated EVA or IXPE layer 6. The wear-resistant paper layer 1 is a wear-resistant paper impregnated with melamine glue, the color film layer 2 is a PVC color film layer, the LVT hard layer 3 is a hard LVT layer formed by mixing and extruding PVC resin with calcium carbonate powder, stabilizer, toughening agent, reinforcing agent, lubricant, etc., and the PVC connecting layer 4 is a PVC connecting film, which can be a white film, wear-resistant, color film or other PVC-type connecting layer. The balancing paper layer 5 is wear-resistant paper impregnated with melamine glue or a balancing paper layer impregnated with melamine glue, and the thickness of the wear-resistant paper layer is 0.05-0.5mm; the thickness of the PVC color film layer and the PVC connecting layer is 0.03-0.1mm; the thickness of the LVT hard layer is 1-10mm; and the thickness of the balancing layer is 0.05-0.5mm. The water-based polyurethane glue is evenly applied to the color film layer 2 (color layer) and the PVC connecting layer 4 (either side) through a special single-sided adhesive coating device, with a coating amount of 5-30g/㎡, and then cured in an oven.

The above-mentioned layers are laminated and formed by hot pressing and compounding, and then the adhesive backing layer is pasted by gluing. If other gloss effects are required on the surface, such as high gloss, a high gloss coating can be applied. The wear-resistant paper layer 1 and the balance paper layer 5 are paved with the adhesive surface of the color film layer 2 and the PVC connection layer 4 respectively, and then connected by high temperature and high pressure melting after paving. The finished product is installed by gluing. The surface of the wall to be pasted is first cleaned of floating dust, and the wall is pre-marked and positioned according to the specifications. When installing, first tear off the anti-sticking paper on the surface of the back sticker EVA or IXPE and apply structural glue in the holes in the back sticker. Stick it on the wall from bottom to top according to the positioning line, and use a glue stick to evenly knock the board surface to make it flat without height difference. It can be put into use after 48 hours of complete curing. The glue can be a neutral silicone structural glue with the brand name JM-995A.

The preparation steps of the composite surface layer structure for wallboard are as follows:

Step 1: The base paper of the wear-resistant paper layer and the balance paper layer is impregnated with melamine glue and then cured through a drying oven, with the impregnation amount being 20-300g/㎡;

Step 2: Apply water-based polyurethane adhesive on one side of the PVC color film and any side of the PVC connection layer, and then solidify them through a drying oven. The coating amount is 5-30g/㎡;

Step 3: Add the materials in the proportion of 30-100 parts of polyvinyl chloride, 100-300 parts of calcium carbonate, 1-10 parts of lubricant, 1-15 parts of stabilizer, 2-10 parts of toughening agent, and 2-10 parts of reinforcing agent, first perform hot mixing at a temperature range of 100-150°C for 30-60 minutes, and then perform cold mixing at less than 50°C. Use a twin-screw extruder to extrude the mixed powder and make a hard LVT layer by calendering to determine thickness, cooling, and cutting;

Step 4: Lay steel plate, canvas, bright film, matte film, melamine impregnated wear-resistant paper layer 1, color film paper layer 2, LVT hard layer 3, PVC connecting layer 4, melamine impregnated balancing paper layer 5, bright film, matte film, embossed template, canvas, etc. in the tray on the hot and cold integrated or split press from bottom to top, and send them into the press for hot pressing and compounding to obtain a semi-finished composite surface layer. The hot pressing temperature is 110-140℃, the hot machine is divided into three sections with a pressure of 6-13Mpa, and the hot machine time corresponding to each pressure section is 10-25min, and the cold machine is also divided into three sections with a pressure of 9-15MP, and the cold machine time corresponding to each pressure section is 10-15min;

Step 5: Place the semi-finished product on the conveyor belt with the back side facing upwards, and evenly roll-coat it with 30-50g/m2 of polyurethane AB glue, with the ratio of the main agent to the curing agent being 4:1 or 5:1. Then spread EVA or IXPE on the adhesive surface, roll it with a soft rubber roller to exhaust the air, and stack them one by one. After curing for 24 hours, proceed with subsequent processing.

Step 6: Cut the bonded semi-finished products into pieces according to the specified specifications, and chamfer and polish them according to customer needs.

The test data of the wallboard prepared according to the above preparation method are shown in Table 1:

Table 1

The test data involved in this application has excellent performance in scratch resistance, impact resistance, environmental protection (formaldehyde content), and stability. It also has basic properties such as fire resistance (B1 grade), waterproof, anti-fouling, smoke resistance, light weight, and quick installation, and has broad market prospects.

Claims (6)

1. A compound surface course structure for wallboard, its characterized in that, this compound surface course structure from the top down is in proper order including wear-resisting ply (1) that the flooding has melamine, the various rete of PVC (2), LVT stereoplasm layer (3), PVC articulamentum (4), the balanced ply (5) that the flooding melamine glued and foraminiferous EVA or IXPE layer (6), wear-resisting ply (1), balanced ply (5) are mated formation with the area face of gluing of the various rete of PVC (2), PVC articulamentum (4) respectively, and it connects through high temperature high pressure melting to mate after accomplishing.

2. The composite skin structure for wall board according to claim 1, characterized in that the thickness of the wear-resistant paper layer (1) is 0.05-0.5mm; the thickness of the PVC color film layer (2) and the thickness of the PVC connecting layer (4) are both 0.03-0.1mm, the thickness of the LVT hard layer (3) is 1-10mm, and the thickness of the balance paper layer (5) is 0.05-0.5mm.

3. The composite face layer structure for the wallboard according to claim 1, wherein the patterned face of the PVC color film layer (2) and any one face of the PVC connecting layer (4) are coated with the aqueous polyurethane glue, and the coating amount is 5-30 g/square meter.

4. A method of making a composite face layer structure for use in wallboard, comprising the steps of:

1) Curing the raw paper of the wear-resistant layer and the balance paper layer through a drying tunnel after melamine glue dipping, wherein the dipping quantity is 20-300g per square meter;

2) Coating one side of the PVC color film layer with the pattern and any side of the PVC connecting layer with a single side of a water-based polyurethane adhesive, and curing through a drying tunnel, wherein the coating quantity is 5-30 g/square meter;

3) The method comprises the following steps of putting materials according to the proportion of 30-100 parts of polyvinyl chloride, 100-300 parts of calcium carbonate, 1-10 parts of lubricant, 1-15 parts of stabilizer, 2-10 parts of toughening agent and 2-10 parts of reinforcing agent, carrying out hot mixing and cold mixing, extruding mixed powder by using a double-screw extruder, and preparing a hard LVT layer by calendering, setting the thickness, cooling and cutting;

4) Laying a steel plate, canvas, a bright film, a delustering film, a melamine impregnated wear-resistant paper layer 1, a color film layer 2, an LVT hard layer 3, a PVC connecting layer 4, a melamine impregnated balance paper layer 5, the bright film, the delustering film, an embossing template and the canvas in sequence from bottom to top in a tray on a cold-hot integrated or split type press, and sending the mixture into the press for hot-pressing compounding to prepare a semi-finished product composite surface layer;

5) Putting the prepared semi-finished product with the back facing upwards into a conveyer belt, uniformly coating 30-50 g/square meter of polyurethane AB glue in a rolling way, wherein the ratio of a main agent to a curing agent of the glue is 4:1 or 5:1, spreading EVA or IXPE on the rubber-bearing surface, rolling and exhausting through a soft rubber roller, stacking in sequence, curing for 24 hours, and then carrying out subsequent processing;

6) Cutting and slicing the attached semi-finished product according to the specified specification, and performing edge chamfering and paint treatment on the chamfered edge.

5. A method of making a composite face structure for wallboard according to claim 4 wherein the hot mix temperature in step 3) is 100-150 ℃ for 30-60 minutes and the cold mix temperature is less than 50 ℃.

6. The method of claim 4, wherein the color surface of the color film layer faces the wear layer during the laying process in step 4), the hot-pressing temperature of the hot-pressing composition is 110-140 ℃, the hot-pressing pressure is 6-13Mpa in three stages, the hot-pressing time corresponding to each stage is 10-25min in sequence, the cold-pressing pressure is 9-15MP in sequence in three stages, and the cold-pressing time corresponding to each stage is 10-15min in sequence.

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