CN116554611A - 一种墙板基材及应用该基材的直印墙板 - Google Patents

一种墙板基材及应用该基材的直印墙板 Download PDF

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CN116554611A
CN116554611A CN202210102867.2A CN202210102867A CN116554611A CN 116554611 A CN116554611 A CN 116554611A CN 202210102867 A CN202210102867 A CN 202210102867A CN 116554611 A CN116554611 A CN 116554611A
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wallboard
parts
layer
substrate
coating
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刘辉煌
刘东岳
刘国俊
黄荣泰
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Jetcoat Shanghai Co ltd China
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Abstract

本发明公开了一种墙板基材及应用该基材的直印墙板，涉及墙板领域，包括基材层，所述基材层的顶部依次设置有密着层、底漆层、印刷层、立体纹层与面漆层，基材层由以下原料份数构成：聚氯乙烯树脂粉100份，碳酸钙粉210‑300份，钙锌复合稳定剂2‑10份，CEP135A抗冲改性剂1.5‑7份，ACR加工助剂1.5‑7份，内润滑剂0.2‑1.5份，外润滑剂0.2‑1.5份，回收料0‑80份。本发明过在基材板上直接做UV印刷、涂装，免去了其它花纹材料的贴合工序，从而避免了胶水的使用造成含甲醛问题，基材板只需通过UV印刷、涂装就能达到不同的花纹和立体纹的一次成型，墙板整体材料都是防水的，透过雕刻的滚筒将UV涂料印到表面达成类似皮革或石头纹路，表面经过功能性UV出料处理可赋予耐污、抗菌等功能。

Description

一种墙板基材及应用该基材的直印墙板
技术领域
本发明涉及墙板领域，具体为一种墙板基材及应用该基材的直印墙板。
背景技术
护墙装饰板是近年来发展起来的新型装饰墙体的材料，一般采用木材等为基材，护墙装饰板具有质轻，防火、防蛀，施工简便，造价低廉，使用安全，装饰效果明显，维护保养方便等优点，它既可代替木墙裙，又可代替壁纸、墙砖等墙体材料，因此使用十分广泛。
传统的墙面装饰材料需要经过贴彩膜或者其它花纹材料的贴合工序，胶水的使用会造成含甲醛问题，且防水、耐污、抗菌性能较差。
发明内容
基于此，本发明的目的是提供一种墙板基材及应用该基材的直印墙板，以解决传统的墙面装饰材料需要经过贴彩膜或者其它花纹材料的贴合工序，胶水的使用会造成含甲醛问题，且防水、耐污、抗菌性能较差的技术问题。
为实现上述目的，本发明提供如下技术方案：一种墙板基材，墙板基材由以下原料及份数构成：
聚氯乙烯树脂粉100份，碳酸钙粉210-300份，钙锌复合稳定剂2-10份，CEP135A抗冲改性剂1.5-7份，ACR加工助剂1.5-7份，内润滑剂0.2-1.5份，外润滑剂0.2-1.5份，回收料0-80份，增白剂0-5份。
本发明进一步设置为，所述墙板基材的制备工艺如下：
步骤一：按照配方组分将原材料投入料斗后首先进入热混机，然后进入冷混机，待原料温度降低到50℃左右后，物料自动转移至储料仓；
步骤二：物料进入双螺杆挤出机后，通过机筒加热和螺杆的剪切力作用下变为熔融状态，此时流体通过模具口形成一定厚度的片状进入四辊压延机，压延机滚筒上可定制不同的纹路，片材通过压延机后正面和背面会形成特定的纹路，供后续工段使用。
本发明进一步设置为，所述步骤一中热混机的热混温度为120-150℃，所述步骤二通过机筒加热的温度为160-200℃。
本发明进一步设置为，所述步骤一中原材料进入热混机经过10-15min后进入冷混机。
本发明还提供如下技术方案：一种直印墙板，包括基材层，所述基材层为上述的墙板基材，所述基材层的顶部依次设置有密着层、底漆层、印刷层、立体纹层与面漆层。
本发明进一步设置为，所述立体纹层也可是平面。
本发明进一步设置为，所述直印墙板的制备工艺如下：
步骤一：将大尺寸的基材层用裁板锯或多片锯裁切成涂装工序所需半成品的尺寸；
步骤二：将需要雕刻的图形输入雕刻机软件中，生成相应的坐标路径，雕刻机会根据对应的路径在裁切好的基材表面雕刻出一定深度和宽度的沟槽，不是所有的直印墙板都需要雕刻；
步骤三：前面工序的平面基材或雕刻后的基材经过180目或240目砂带抛光和毛刷的清洁后进入滚涂机和紫外光固化机，依次为密着层、底漆层、印刷层、立体纹层、面漆层，透过雕刻的滚筒将UV涂料印到表面达成类似皮革或石头纹路。
本发明进一步设置为，每滚涂一道涂料后都会经过紫外光固化机立即固化。
本发明进一步设置为，UV涂料的涂布量5-200g/㎡不等，依产品的表面效果和性能要求而定。
综上所述，本发明主要具有以下有益效果：
1.本发明通过在基材板上直接做UV印刷、涂装，免去了贴彩膜或者其它花纹材料的贴合工序，从而避免了胶水的使用造成含甲醛问题，基材板只需通过UV印刷、涂装就能达到不同的花纹和立体纹的一次成型，节约了人力和能源，墙板整体材料都是防水的，透过雕刻的滚筒将UV涂料印到表面达成类似皮革或石头纹路，表面经过功能性UV出料处理可赋予耐污、抗菌等功能；
2.本发明墙板的生产过程能耗相对较低，施工过程简单快捷且不会产生建筑垃圾，旧墙板拆除后材料可以收回用于其它低端产品的制造。
附图说明
图1为本发明墙板的层面结构示意图。
图中：1、基材层；2、密着层；3、底漆层；4、印刷层；5、立体纹层；6、面漆层。
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。下面通过参考附图描述的实施例是示例性的，仅用于解释本发明，而不能理解为对本发明的限制。
下面根据本发明的整体结构，对其实施例进行说明。
实施例1
一种墙板基材，其由以下原料及份数构成：
聚氯乙烯树脂粉100份，碳酸钙粉300份，钙锌复合稳定剂9份，CEP135A抗冲改性剂4份，ACR加工助剂5份，内润滑剂1份，外润滑剂1份，回收料80份，增白剂1份。
墙板基材的制备工艺如下：
步骤一：按照配方组分将原材料投入料斗后首先进入热混机，热混温度为120-150℃，经过10-15min后进入冷混机，待原料温度降低到50℃左右后，物料自动转移至储料仓；
步骤二：物料进入双螺杆挤出机后，通过机筒加热(160-200℃)和螺杆的剪切力作用下变为熔融状态，此时流体通过模具口形成一定厚度的片状进入四辊压延机，压延机滚筒上可定制不同的纹路，片材通过压延机后正面和背面会形成特定的纹路，供后续工段使用。
实施例2
一种墙板基材，其由以下原料及份数构成：
聚氯乙烯树脂粉100份，碳酸钙粉300份，钙锌复合稳定剂9份，CEP135A抗冲改性剂2份，ACR加工助剂4份，内润滑剂1份，外润滑剂1份，回收料80份，增白剂1份。
墙板基材的制备工艺如下：
步骤一：按照配方组分将原材料投入料斗后首先进入热混机，热混温度为120-150℃，经过10-15min后进入冷混机，待原料温度降低到50℃左右后，物料自动转移至储料仓；
步骤二：物料进入双螺杆挤出机后，通过机筒加热(160-200℃)和螺杆的剪切力作用下变为熔融状态，此时流体通过模具口形成一定厚度的片状进入四辊压延机，压延机滚筒上可定制不同的纹路，片材通过压延机后正面和背面会形成特定的纹路，供后续工段使用。
实施例1与实施例2对比，改变的是基材的韧性和抗冲击性能。
实施例3
一种直印墙板，包括基材层1，基材层1为实施例1或实施例2中的墙板基材，基材层1的顶部依次设置有密着层2、底漆层3、印刷层4、立体纹层5与面漆层6。
直印墙板的制备工艺如下：
步骤一：将大尺寸的基材层1用裁板锯或多片锯裁切成涂装工序所需半成品的尺寸；
步骤二：将需要雕刻的图形输入雕刻机软件中，生成相应的坐标路径，雕刻机会根据对应的路径在裁切好的基材表面雕刻出一定深度和宽度的沟槽，不是所有的直印墙板都需要雕刻；
步骤三：前面工序的平面基材或雕刻后的基材经过180目或240目砂带抛光和毛刷的清洁后进入滚涂机和紫外光固化机，依次为密着层2、底漆层3、印刷层4、立体纹层5、面漆层6，每滚涂一道涂料后都会经过紫外光固化机立即固化，UV涂料的涂布量5-75g/㎡不等，依产品的表面效果和性能要求而定。
实施例4
将本发明直印墙板样品与市面上的外来2种样品进行对比测试，结果如下表所示：
由上表可知，本发明直印墙板样品相比于外来2种样品，柔韧性更好，且耐污性能突出，在气味测试方便也无异常气味，在水煮及高温高湿实验后，本发明样品漆膜不会脱离，由此可见，依照本发明方法制得的墙板优于市场上的墙板。
尽管已经示出和描述了本发明的实施例，但本具体实施例仅仅是对本发明的解释，其并不是对发明的限制，描述的具体特征、结构、材料或者特点可以在任何一个或多个实施例或示例中以合适的方式结合，本领域技术人员在阅读完本说明书后可在不脱离本发明的原理和宗旨的情况下，可以根据需要对实施例做出没有创造性贡献的修改、替换和变型等，但只要在本发明的权利要求范围内都受到专利法的保护。

Claims (9)

1.一种墙板基材，其特征在于：墙板基材由以下原料及份数构成：
聚氯乙烯树脂粉100份，碳酸钙粉210-300份，钙锌复合稳定剂2-10份，CEP135A抗冲改性剂1.5-7份，ACR加工助剂1.5-7份，内润滑剂0.2-1.5份，外润滑剂0.2-1.5份，回收料0-80份，增白剂0-5份。
2.根据权利要求1所述的一种墙板基材，其特征在于：所述墙板基材的制备工艺如下：
步骤一：按照配方组分将原材料投入料斗后首先进入热混机，然后进入冷混机，待原料温度降低到50℃左右后，物料自动转移至储料仓；
步骤二：物料进入双螺杆挤出机后，通过机筒加热和螺杆的剪切力作用下变为熔融状态，此时流体通过模具口形成一定厚度的片状进入四辊压延机，压延机滚筒上可定制不同的纹路，片材通过压延机后正面和背面会形成特定的纹路，供后续工段使用。
3.根据权利要求2所述的一种墙板基材，其特征在于：所述步骤一中热混机的热混温度为120-150℃，所述步骤二通过机筒加热的温度为160-200℃。
4.根据权利要求2所述的一种墙板基材，其特征在于：所述步骤一中原材料进入热混机经过10-15min后进入冷混机。
5.一种直印墙板，包括基材层(1)，其特征在于：所述基材层(1)为权利要求1-3任意一项所述的墙板基材，所述基材层(1)的顶部依次设置有密着层(2)、底漆层(3)、印刷层(4)、立体纹层(5)与面漆层(6)。
6.根据权利要求5所述的一种直印墙板，其特征在于：所述立体纹层(5)也可是平面。
7.根据权利要求6所述的一种直印墙板，其特征在于：所述直印墙板的制备工艺如下：
步骤一：将大尺寸的基材层(1)用裁板锯或多片锯裁切成涂装工序所需半成品的尺寸；
步骤二：将需要雕刻的图形输入雕刻机软件中，生成相应的坐标路径，雕刻机会根据对应的路径在裁切好的基材表面雕刻出一定深度和宽度的沟槽，不是所有的直印墙板都需要雕刻；
步骤三：前面工序的平面基材或雕刻后的基材经过180目或240目砂带抛光和毛刷的清洁后进入滚涂机和紫外光固化机，依次为密着层(2)、底漆层(3)、印刷层(4)、立体纹层(5)、面漆层(6)，透过雕刻的滚筒将UV涂料印到表面达成类似皮革或石头纹路。
8.根据权利要求7所述的一种直印墙板，其特征在于：每滚涂一道涂料后都会经过紫外光固化机立即固化。
9.根据权利要求7所述的一种直印墙板，其特征在于：UV涂料的涂布量5-200g/㎡不等，依产品的表面效果和性能要求而定。
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