WO2022227174A1 - 仿真美缝的加工方法、仿真板材及仿真板材组 - Google Patents

仿真美缝的加工方法、仿真板材及仿真板材组 Download PDF

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Publication number
WO2022227174A1
WO2022227174A1 PCT/CN2021/096664 CN2021096664W WO2022227174A1 WO 2022227174 A1 WO2022227174 A1 WO 2022227174A1 CN 2021096664 W CN2021096664 W CN 2021096664W WO 2022227174 A1 WO2022227174 A1 WO 2022227174A1
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WIPO (PCT)
Prior art keywords
groove
hot pressing
plate
chamfering
heat transfer
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PCT/CN2021/096664
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English (en)
French (fr)
Inventor
戴会斌
章忠飞
董利杰
王涛
李猛飞
曹江川
Original Assignee
浙江晶通新材料集团有限公司
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Publication of WO2022227174A1 publication Critical patent/WO2022227174A1/zh

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41F—PRINTING MACHINES OR PRESSES
    • B41F16/00—Transfer printing apparatus
    • B41F16/0006—Transfer printing apparatus for printing from an inked or preprinted foil or band
    • B41F16/0073—Transfer printing apparatus for printing from an inked or preprinted foil or band with means for printing on specific materials or products
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41F—PRINTING MACHINES OR PRESSES
    • B41F16/00—Transfer printing apparatus
    • B41F16/0006—Transfer printing apparatus for printing from an inked or preprinted foil or band
    • B41F16/0093—Attachments or auxiliary devices
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44F—SPECIAL DESIGNS OR PICTURES
    • B44F9/00—Designs imitating natural patterns
    • B44F9/02—Designs imitating natural patterns wood grain effects
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44F—SPECIAL DESIGNS OR PICTURES
    • B44F9/00—Designs imitating natural patterns
    • B44F9/04—Designs imitating natural patterns of stone surfaces, e.g. marble
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/10—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials

Definitions

  • the invention relates to the technical field of flooring, in particular to a processing method for simulating beautiful seams, a simulated board and a set of simulated boards.
  • Wood-based panels are more and more widely used in the field of decoration, such as floors and walls.
  • the PVC board is light in weight, easy to install, waterproof, moisture-proof, and moth-proof.
  • the surface has a variety of designs and patterns, and has good performance such as pollution resistance, flame retardant, sound insulation, and heat insulation, while the SPC (soft composite board) board is hard.
  • the abbreviation of multi-layer composite PVC sheet is a product made of PVC color film, PVC wear-resistant layer and PVC bottom film at one time. The process is simple, the bonding is completed by heat, and does not contain glue.
  • the shapes of the gaps of the existing boards are all V-shaped grooves, so that there is no gap between the boards. There is no visual effect of beautiful seams, and in real life, if the seam is not welded, the small gaps left will bring great inconvenience to cleaning, and the liquid will easily seep from the gaps, affecting the service life of the PVC board. .
  • the lock-type PVC sheet can directly interlock the sheets, which is particularly convenient for construction.
  • the visual effect of the beautiful seam of the existing lock-type PVC sheet is not ideal, especially when installing the SPC sheet against marble and other tiles, if there is no visual effect of the beautiful seam of the tile, the SPC sheet cannot be The visual experience is consistent with the tiles.
  • the purpose of the present invention is to provide a processing method for simulating a beautiful seam, which can make at least a part of the board have the visual effect of a beautiful seam. .
  • the present invention provides a processing method for simulating a beautiful seam, which includes a chamfering treatment step and a coloring step.
  • the chamfering treatment step includes chamfering at least one edge of the surface of the sheet to obtain a groove, and
  • the groove includes at least one section of concave arc surface, and the groove width of the groove is 3.0mm-20mm;
  • the coloring step includes coloring the inner wall of the groove by using a thermal transfer printing process to form a simulated beautiful seam.
  • the processing method of simulated beautiful seam provided in the present invention is applicable to but not limited to PVC board, polypropylene (PP) board, ABS (Acrylonitrile-butdiene-styrene) board, etc., and is especially suitable for rigid sheet board in PVC board, such as SPC board can also be applied to PP board.
  • the hardness of SPC board and PP board is relatively high, and the board is not easily deformed during thermal transfer.
  • semi-rigid sheets such as LVT board and WPC board can also be used Plastic boards, but LVT boards and WPC boards are easily deformed during thermal transfer.
  • the chamfers are prone to barbs, which affect the appearance and the adhesion of the coloring layer.
  • Colors to be colored in the coloring step of the present invention include but are not limited to gray, black, white, and light gray, and the color of coloring is selected according to actual needs, wherein gray is close to the color of the cement material.
  • the groove width of the groove in the present invention can be 3.8mm, 4mm, 5mm, 10mm, 8mm, 15mm, 13mm and so on.
  • the slit width of the existing plates is very small, the width of the slit is less than 4.0mm, and some are even less than 3mm, and for the convenience of processing, the shape of the slit is a V-shaped groove, that is to say, the existing The chamfers of the plates are all plane chamfers, and the width of the plane chamfers are all less than 2mm, and some are even less than 1.5mm.
  • the present application overcomes the inherent prejudice in the field.
  • a wider groove (groove width is 3.0mm-20mm) is set on the surface of the plate, and the The transfer printing is done on the inner wall of the groove, and by setting the concave arc surface, which is concave toward the direction of the plate, the final groove has a visual effect similar to that of the beautiful tile seam.
  • the width of the plane chamfer in the prior art is relatively small, if the transfer is done on the plane chamfer, the transferred color can easily overflow the position of the plane chamfer.
  • the transferred color is easy to overflow, and the two ends of the concave arc surface in the present application form two sharp acute angles, and the transferred color is not easy to overflow.
  • the chamfering step can be omitted if the plate is already provided with the grooves that meet the conditions.
  • the groove is a concave arc-shaped groove, and the corresponding central angle of the arc-shaped groove is 30°-60°, preferably, it can be set to 45°, 48°, 40°, 50° and so on.
  • the angle between the arc-shaped groove and the surface of the plate is 15°-30°, preferably, it can be set to 20°, 25°, 28°, 18°, etc., so that the transferred color is not easy to overflow.
  • the groove depth of the circular arc groove is 0.5mm-2mm, preferably, it can be set to 0.8mm, 1mm, 1.5mm, 1.2mm and so on.
  • the groove includes a concave arc surface and a section or at least two planes, the concave arc surface accounts for more than 80% of the width of the entire groove, and in some embodiments, it reaches more than 90%, or even More than 95%; when the plane is a section, the side of the concave arc surface away from the side of the plate is connected to the plane, and the angle between the plane and the surface of the plate is 15°-30°; when the plane is at least two sections , the two sides of the concave arc surface are respectively connected with the two planes, and the included angle between the plane and the surface of the plate is 15°-30°.
  • the size of the included angle between the two sides of the arc-shaped groove and the surface of the plate is different, that is, the arc-shaped groove in the present application is asymmetrically arranged.
  • the included angle close to the side edge of the plate is smaller than the included angle away from the side edge, which is favorable for smooth transition, but in other embodiments, the included angle close to the side edge can also be larger than the included angle away from the side edge.
  • the edge to be chamfered is defined as the first edge
  • the processing method further includes chamfering the second edge of the surface of the plate, the second edge and the first edge are respectively located on opposite sides of the plate,
  • the angle and depth of the bevels are matched to the shape and size of the grooves to achieve a smooth connection of adjacent spliced panels.
  • the angle of the bevel is smaller than the included angle, and further, the angle of the bevel is less than 30°, the smaller the bevel, the shallower the bevel, and the less obvious the bevel, but correspondingly, the larger the bevel is .
  • bevel is a plane bevel.
  • the arrangement of the bevel and the arc-shaped groove is beneficial to the buckling of the clasp mentioned below.
  • the processing method further includes a second chamfering processing step, the second chamfering processing step is provided between the chamfering processing step and the coloring step, and the second chamfering processing step includes:
  • the second chamfering is performed at the position where the corners meet to obtain a transition arc for smooth connection with the bevel, so that the width of the bevel is less than or equal to 1/3 of the groove width of the arc-shaped groove, and the width direction of the bevel is the same as that of the bevel.
  • the direction of the groove width of the arc-shaped groove is consistent.
  • the width of the bevel can be set to be less than or equal to 1/4, or even 1/5, of the groove width of the arc-shaped groove.
  • the width of the bevel is very small, about 0.5mm-2mm, and the width of the bevel is consistent with the direction of the groove width of the groove, or the bevel in this application is difficult to observe with the naked eye, so through the transition
  • the bevel in the present invention does not require additional coloring treatment, so the plate of the present application only needs to be colored on half of its edges, which is convenient for processing.
  • the transition arc is more upturned than the arc groove, which further prevents the transferred color from overflowing.
  • the first edge and the second edge are parallel to each other and there are at least two pairs of the first edge and the second edge, and the step of chamfering includes chamfering at least two adjacent first edges on the surface of the board to At least two adjacently arranged grooves are obtained, and the second edge does not need to be colored, and the grooves here are linear, which is convenient for pipeline operations.
  • the grooves may also be arc-shaped.
  • the coloring step is carried out on a heat transfer machine, which includes a heat press, a conveying mechanism and a ribbon winding device.
  • a support plate made of material for the application of the rollers.
  • a hot pressing part is correspondingly arranged in the conveying direction of the plate, and the ribbon winding device is used to lay the ink ribbon on the groove of the plate along the conveying direction;
  • the coloring step includes the adjustment step of the hot pressing part and the hot pressing step,
  • the adjusting step of the pressing piece includes adjusting the position of the hot pressing piece so that the hot pressing piece corresponds to the groove;
  • the temperature of the hot-pressed part is 150°C-380°C.
  • the heat transfer machine further includes a dust removal mechanism, and the board is dedusted by the dust removal mechanism between the coloring steps.
  • the adjustment steps of the hot-pressed parts can be interspersed throughout the machining line production process.
  • the thermal transfer machine may also include an induction mechanism and a main control mechanism. The induction device is used to sense the position of the plate, and the main control mechanism controls the operation of the roller according to the information transmitted by the induction device.
  • the extending direction of the groove and the first edge is consistent, and the groove always extends on the entire first edge, which is also convenient for assembly line operation.
  • the hot pressing part includes an elastic roller, the linear speed of the rotation of the roller is in the range of 5m/min-30m/min, as an option, the elastic roller is made of rubber, the linear speed of the rotation of the roller and The conveying speed of the plate is equal or the linear speed of the rotation of the roller is slightly less than the conveying speed of the plate, and the speed of the ribbon winding device is equal to the conveying speed of the plate.
  • the elastic roller is made of rubber, the linear speed of the rotation of the roller and The conveying speed of the plate is equal or the linear speed of the rotation of the roller is slightly less than the conveying speed of the plate, and the speed of the ribbon winding device is equal to the conveying speed of the plate.
  • the elastic roller is made of rubber, the linear speed of the rotation of the roller and The conveying speed of the plate is equal or the linear speed of the rotation of the roller is slightly less than the conveying speed of the plate, and the speed of the ribbon winding device is equal to the conveying speed of the plate.
  • Made of rubber it is
  • the hot pressing parts are subjected to multiple passes, and one or more of the heat transfer machines include a plurality of rollers.
  • the heat transfer machines include a plurality of rollers.
  • multiple heat pressing can increase the adhesion of the transferred coloring layer.
  • the coloring step further includes a step of adjusting the pressure of the hot-pressed part, the pressure-adjusting step is located before the hot-pressing step, and the pressure-adjusting step includes adjusting the height of the hot-pressed part to the plate to adjust the pressure of the hot-pressed part to the plate when it is pressed down.
  • the size of the pressure, the size of the pressure should at least ensure that the coloring layer has good adhesion.
  • thermal transfer machines there are at least two thermal transfer machines.
  • there are two thermal transfer machines which are the first thermal transfer machine and the second thermal transfer machine, respectively.
  • the plates in the two thermal transfer machines are The conveying directions of the two adjacent first edges are respectively parallel to the directions of the two adjacent first edges.
  • the conveying mechanisms in the two thermal transfer machines are connected, and the two adjacent grooves are defined as the first groove and the second groove, respectively.
  • the coloring step includes the adjustment of the hot pressing parts, the first hot pressing machine and the second hot pressing; the adjustment of the hot pressing parts includes adjusting the positions of the hot pressing parts of the two heat transfer machines so that the hot pressing parts correspond to the first grooves respectively and the second groove; the first hot pressing includes transferring the ink color layer of the ribbon to the inner wall of the first groove by the hot pressing of the hot pressing part of the first heat transfer machine; the second hot pressing includes passing the first The hot pressing piece after hot pressing is transferred to the second heat transfer machine, and the hot pressing of the hot pressing piece of the second heat transfer machine transfers the ink layer of the ribbon to the inner wall of the second groove;
  • the temperature ranges of the hot-pressed parts in the first hot-pressing and the second hot-pressing are both 150°C-380°C, and the temperatures of the hot-pressing parts in the first hot-pressing and the second hot-pressing can be 200°C, 250°C, 180°C °C and other arbitrary values.
  • the processing method further includes a step of punching the fastener, the step of punching the fastener and the step of chamfering are performed simultaneously, or the step of punching the fastener is arranged before the step of chamfering, or is arranged after the step of chamfering but before the coloring step.
  • the fasteners obtained in the step of punching the fasteners were used for the fastening of adjacent plates, and the inner wall of the arc-shaped groove extended along the thickness direction of the plate to the bottom surface of the plate, which were all solid structures, so that the plate was not easily deformed.
  • the step of punching the fastener and the step of chamfering are performed simultaneously.
  • the thickness of the plate is not less than 4.5mm, and the plate with too small thickness is easily deformed or broken during the hot pressing process.
  • the present invention also provides a simulation board, which is prepared by coating with any of the above-mentioned processing methods for simulating beautiful seams. At least one edge of the surface of the simulation board is provided with a groove, and the groove includes at least a concave arc surface. , and the groove width is 3.0mm-20mm, and the inner wall of the groove is coated with a coloring layer.
  • the present invention also provides a simulation plate assembly, which is obtained by splicing a plurality of the same simulation plates as described above, and the plates of the connected simulation plates are spaced by a groove.
  • the simulation plate is a parallelogram, and further, the simulation plate is a rectangle or even a square, and two adjacent first edges of the simulation plate are respectively provided with adjacent first grooves and second grooves.
  • the simulated boards are the same, and the connected simulated boards are separated by the first groove or the second groove.
  • the simulated plate may also be any other shape such as a trapezoid, a triangle, a circle, or the like.
  • the present invention overcomes the inherent prejudice in the art.
  • a wider groove (groove width is 3.0mm-20mm) is set on the surface of the plate, And by transferring the color on the inner wall of the groove, and the concave arc surface makes the final groove visually similar to the beautiful tile seam.
  • the grooves provided in the present application are concave toward the direction of the plate, and the transfer color is not easy to overflow.
  • the simulation board with the simulation beauty seam and the simulation board assembly formed by the splicing thereof prepared by the processing method of the simulation beauty seam of the present invention have visual effects similar to those of the beauty seam of tiles, wood boards, etc. Set the corresponding patterns and patterns on it, and finally make it have a similar visual effect with tiles, wooden boards, etc.
  • Fig. 1 is the process flow diagram of the processing method provided by Embodiment 1 of the present invention.
  • Fig. 2 is the top view of the simulated plate with simulated beautiful seam after the chamfering process and after the coloring step provided by the first embodiment of the present invention
  • FIG. 3 is a side view of the chamfered plate provided by the first embodiment of the present invention.
  • Fig. 4 is the schematic diagram of the simulation board provided by the second embodiment of the present invention.
  • FIG. 5 is a schematic diagram of a simulated plate assembly spliced by a splicing method provided by the second embodiment of the present invention.
  • FIG. 6 is a schematic diagram of a simulated plate assembly spliced by another splicing method provided in Embodiment 2 of the present invention.
  • Fig. 7 is one of the radial cross-sectional views along the arc-shaped groove of the simulation plate group provided by the third embodiment of the present invention.
  • FIG. 9 is a radial cross-sectional view of the simulation plate group along the arc-shaped groove provided by the fourth embodiment of the present invention.
  • FIG. 10 is a schematic diagram of a layered structure of a ribbon provided by an embodiment of the present invention.
  • FIG. 12 is the second schematic diagram of the roller provided by the embodiment of the present invention.
  • the surface in the present invention refers to the side of the sheet that is exposed to the outside world or that can be seen by the user, and the bottom surface in the present invention refers to the side opposite to the surface.
  • the groove width direction of the groove in the present invention is perpendicular to the extending direction of the groove.
  • the first embodiment provides a processing method for simulating a beautiful seam, including a chamfering processing step S01 and a coloring step S02.
  • the chamfering processing step S01 includes chamfering one of the edges of the surface of the plate 100 to obtain a
  • the groove 102 the groove includes at least a section of concave arc surface, and the groove width of the groove is 3.0mm-20mm
  • the coloring step S02 includes using a thermal transfer process to color the inner wall of the groove to form a simulated beautiful seam 101 to obtain a simulation Sheet
  • Figure 2 shows a top view of a simulated sheet with a simulated beautiful seam after chamfering and coloring steps
  • Figure 3 shows a side view of the chamfered sheet
  • Figures 2 and 3 The middle wavy line is only used as the boundary line of the fracture, and does not make any restrictions on the shape of the plate.
  • the coloring step in this embodiment includes an adjustment step of the hot-pressed part and a hot-pressing step
  • the adjustment step of the hot-pressed part includes adjusting the position of the hot-pressed part so that the hot-pressed part corresponds to the groove
  • the hot-pressing step includes The ink layer of the ribbon laid on the groove is transferred to the inner wall of the groove by the hot pressing of the hot pressing part.
  • the adjustment step of the hot-pressed part can be omitted.
  • the simulated beautiful seam prepared in this example can be found to have insignificant asymmetry in the naked eye observation, but it is still within an acceptable range.
  • the second embodiment provides a processing method for simulating a beautiful seam of a rectangular plate, and the provided plate has been provided with a fastener for splicing adjacent plates, and the fastener is provided in a shape and The position is such that the part under the groove is a solid structure, that is, the inner wall of the groove extends along the thickness H direction of the plate to the bottom surface of the plate.
  • the processing method in this embodiment includes a chamfering treatment step and a coloring step, and the coloring step includes the adjustment of the hot-pressed part, the first hot-pressing, and the second hot-pressing.
  • the processing method specifically includes the following steps:
  • Step of chamfering treatment the two adjacent first edges of the surface of the sheet are chamfered respectively to obtain two grooves, namely the first groove and the second groove, and the grooves are all concave circles. arc-shaped grooves, and the groove widths of the grooves are consistent, and the groove widths L1 of the grooves in this embodiment are all 3.8mm;
  • Adjustment of the hot pressing parts adjust the positions of the hot pressing parts of the two heat transfer machines so that the hot pressing parts correspond to the first groove and the second groove respectively;
  • the first hot pressing transfer the ink color layer of the ribbon to the inner wall of the first groove by the hot pressing of the hot pressing part of the first heat transfer machine;
  • Second hot pressing The hot pressing part after the first hot pressing is transferred to the second heat transfer machine, and the hot pressing of the hot pressing part of the second heat transfer machine transfers the ink layer of the ribbon to the second concave On the inner wall of the groove; wherein, the temperature range of the hot pressing parts in the first hot pressing and the second hot pressing is 150°C-380°C. In this embodiment, both the first hot pressing and the second hot pressing have two passes.
  • the present embodiment also provides a simulated sheet.
  • the thicker lines in the figure represent simulated beautiful seams, which are prepared by coating with the above-mentioned processing method for simulated beautiful seams.
  • the two first edges of the The groove width is 3.8mm, and the inner wall of the groove is coated with a glossy coloring layer.
  • the simulated beautiful seam prepared in this example can be found to have insignificant asymmetry in the naked eye observation, but it is still within an acceptable range.
  • the present invention also provides a simulation plate assembly, which is obtained by splicing a plurality of the same simulation plates as described above, and the plates of the connected simulation plates are spaced by a groove, and Adhesion test structures achieved good results.
  • the processing method in the third embodiment further includes a chamfering processing step, and the chamfering processing step is between the chamfering processing step and the coloring step.
  • the corner processing steps can be performed simultaneously.
  • the second edge and the first edge are set opposite to each other, and the setting of the bevel helps to fasten the adjacent plates.
  • FIGS. 7 and 8 The radial cross-sectional views of the prepared simulation plate group along the arc-shaped groove are shown in FIGS. 7 and 8 . There is no smooth connection between the bevel 500 and the arc-shaped groove 400 . In the naked eye observation, it can be found that there is no obvious asymmetry, but it is still within an acceptable range.
  • the central angle ⁇ corresponding to the arc-shaped groove is 48°, and the included angle ⁇ between the arc-shaped groove and the surface of the plate is 30°, and the groove depth H1 of the arc-shaped groove is 0.8 mm.
  • the processing method in Embodiment 4 further includes a second chamfering processing step.
  • the second chamfering processing step and the chamfering processing step are performed simultaneously,
  • the second chamfering processing step includes: performing second chamfering on the position where the bevels of the arc-shaped grooves meet to obtain a transition arc 401 for smooth connection with the bevel.
  • the transition arc in this embodiment corresponds to The central angle is also included in the corresponding central angle of the arc-shaped groove, so that the width L2 of the bevel is less than or equal to 1/3 of the groove width of the arc-shaped groove, and the width direction of the bevel and the width of the arc-shaped groove.
  • the direction of the groove width is the same.
  • the groove width of the bevel in this embodiment is very small, which is 1.2 mm. In this application, it is difficult to observe the bevel when observing with the naked eye.
  • this The bevel in the invention does not need additional coloring treatment, so the plate of the present application only needs to be colored on half of its edges, which is convenient for processing. Furthermore, the transition arc is more upturned than the arc groove, which further prevents the transferred color from overflowing.
  • the angle ⁇ and the depth H2 of the bevel setting match the shape and size of the groove to achieve smooth connection of adjacent plates.
  • the angle of the oblique angle is smaller than the included angle. Further, the angle of the oblique angle in this embodiment is 25°. The smaller the inclination, the shallower the oblique angle, and the less obvious the oblique angle. The larger the width of the corner, the need to cooperate with the transition arc to rationalize the size design of the width and depth of the bevel, and finally realize that the bevel is invisible to the naked eye or invisible to the naked eye.
  • the radial cross-sectional view of the prepared simulation plate group along the arc-shaped groove is shown in Figure 9, and the dotted line in Figure 9 shows the limit of the arc-shaped groove if the second chamfering process is not performed , the bevels and the arc-shaped grooves in this embodiment are smoothly connected, and the simulated beautiful seams prepared in this embodiment have visual effects similar to those of the beautiful seams in the naked eye observation, and there is no color at all when coloring overflow.
  • the fifth embodiment provides a processing method for simulating a beautiful seam of a rectangular plate, but the provided plate is not provided with a fastener 600 for splicing adjacent plates. Therefore, on the basis of the processing method of the second embodiment, the step of punching the fastener is also included.
  • the step of punching the fastener, the chamfering treatment step, and the chamfering treatment are all performed simultaneously.
  • the fastener step, the chamfering processing step, and the chamfering processing can also be performed in steps, for example, the fastener punching step can also be set before the chamfering processing step, or after the chamfering processing step but before the coloring step.
  • the fasteners obtained in the step of punching the fasteners are used for the fastening of adjacent plates, and the inner walls of the arc-shaped grooves extend along the thickness direction of the plates to the bottom surface of the plates are solid structures, so that the plates are not easily deformed.
  • the bevel and the arc-shaped groove are smoothly connected.
  • the simulated beautiful seam prepared in this example has a visual effect similar to that of the beautiful seam when observed with the naked eye, and there is no color overflow during coloring.
  • the angle of the bevel provided in Embodiment 6 is 75°, the width of the bevel is very small, 0.3 mm, and similarly, the bevel is not clearly visible.
  • the width of the circular arc groove provided in the seventh implementation is 8 mm
  • the central angle ⁇ corresponding to the circular arc groove is 60°
  • the angle between the circular arc groove and the surface of the plate is 60°.
  • ⁇ is 20°
  • the groove depth H1 of the arc-shaped groove is 0.8mm.
  • the bevel and the arc-shaped groove are smoothly connected.
  • the simulated beautiful seam prepared in this example has a visual effect similar to that of the beautiful seam when observed with the naked eye, and there is no color overflow during coloring.
  • Comparative Example 1 The difference between Comparative Example 1 and Example 2 is that the groove of Comparative Example 1 is a plane bevel, but the final sheet has color overflow at the position other than the beautiful seam, and there is no effect of imitating the beautiful seam at all.
  • Comparative Example 2 The difference between Comparative Example 2 and Example 2 is that the groove of Comparative Example 1 is an upwardly convex arc-shaped groove, but the final obtained plate has color overflow at the position other than the beautiful seam, and the beautiful seam is imitated. Ineffective.
  • Comparative Example 3 The difference between Comparative Example 3 and Example 2 is that the position of the fastener extends on the lower side of the groove, and the groove is colored by spraying, but the colored layer obtained by spraying has no luster and poor adhesion.
  • the heat transfer machine includes a heat press part, a conveying mechanism and a ribbon winding device.
  • the conveying mechanism is used to convey the plate, and a heat press is correspondingly arranged in the conveying direction of the plate.
  • the ribbon take-up device is used to lay the ribbon on the groove of the plate along the conveying direction.
  • the thermal transfer machine further includes a dust removal mechanism, and the board is dedusted by the dust removal mechanism between the coloring steps.
  • the hot pressing parts in all the examples and comparative examples in the present invention are rollers with elasticity, and the linear speed range of the rotation of the rollers is 5m/min-30m/min.
  • the roller consists of two parts, the outer ring and the inner ring.
  • the part of the outer ring 32 in contact with the plate is made of rubber, and the part of the inner ring 31 used for installation and connected to the rotating shaft is made of metal material. If the roller is damaged or deformed, The outer ring can be re-grinded for reuse.
  • the rotational linear speed of the roller is equal to the conveying speed of the plate or the rotational linear speed of the roller is slightly lower than the conveying speed of the plate, and the speed of the ribbon winding device is equal to the conveying speed of the plate.
  • edges of both sides of the outer ring of the roller are respectively provided with a ridge 321, and the shape of the ridge corresponds to the groove, so that the roller can completely fit the color transfer layer of the ink ribbon to the inner wall of the groove.
  • the ribbons in all the examples and comparative examples of the present invention have a four-layer structure, which are sequentially: a PET film 21 and a color transfer layer, and the color transfer layer includes a UV layer 22, an ink layer 23, and a glue Layer 24. And the width of the ribbon used in all examples and comparative examples is slightly larger than the length of the expanded inner wall of the groove.
  • the color transfer layer may contain polyethylene wax and EVA wax.
  • thermal printing machines in each of the other embodiments which are the first thermal printing machine and the second thermal printing machine, respectively.
  • the conveying directions of the plates in the machine are respectively parallel to the directions of the two adjacent first edges, and the conveying mechanisms in the two heat transfer machines are connected and can be used for continuous conveying and production.
  • the measurement methods of the simulated beautiful seams prepared in each embodiment and each comparative example are divided into visual observation of color overflow, visual observation of glossiness, visual observation of wrinkles and evaluation of adhesion.
  • the adhesion evaluation test can be roughly divided into the following three levels:
  • the simulated beautiful seams obtained in all the examples are glossy, and the transferred coloring layer has no obvious wrinkles, and there is no obvious color overflow phenomenon.

Abstract

本发明提供一种仿真美缝的加工方法、仿真板材及仿真板材组。包括倒角处理步骤及着色步骤，倒角处理步骤包括将板材的表面的至少一个边沿进行倒角处理以获得凹槽，凹槽包括至少一段凹形弧面，并且凹槽的槽宽为3.0mm-20mm；着色步骤包括采用热转印工艺对凹槽的内壁进行着色形成仿真美缝。

Description

仿真美缝的加工方法、仿真板材及仿真板材组 技术领域
本发明涉及地板技术领域，尤其是一种仿真美缝的加工方法、仿真板材及仿真板材组。
背景技术
人造板在装修领域，例如地板、墙面上都有越来越广泛的应用。其中的PVC板量轻、安装简便、防水防潮、防蛀虫，表面的花色图案多样，并具有耐污染、阻燃、隔声、隔热等良好性能，而SPC(soft composite board)板材是硬质多层复合PVC板材的简称，是由PVC彩膜、PVC耐磨层、PVC底膜一次性压贴复合而成的产品，工艺简单、贴合靠热量完成，不含胶水。
但是现有的PVC板在安装时，相接的板材和板材之前不留缝隙或者留的缝隙很小，为了便于焊接，现有的板材的缝隙的形状都为V形槽，这样板材之间就不存在美缝的视觉效果，而且实际生活中，如果不进行焊缝的话，留下的细小的缝隙给打扫带来很大的不便，液体也容易从缝隙中下渗，影响PVC板的使用寿命。
再者，简单的PVC板材在施工时还需要放线、铺贴、焊缝等一系列操作，施工较为费时。但是锁扣式PVC板材可以直接将板材相扣，施工特别方便。但是现有的锁扣式PVC板材的美缝的视觉效果也不理想，尤其是在防大理石等瓷砖的SPC板材的安装的时候，如果没有贴瓷砖的美缝的视觉效果，SPC板材就不能在视觉感受上和瓷砖达到一致。
发明内容
本发明的目的是提供一种仿真美缝的加工方法，可以使板材的至少一部分具有美缝的视觉效果，本发明的目的还在于提供一种使用美缝方法制备得到的仿真板材和仿真板材组。
为了解决上述技术问题，本发明提供一种仿真美缝的加工方法，包括倒角处理步骤及着色步骤，倒角处理步骤包括将板材的表面的至少一个边沿进行倒角处理以获得凹槽，凹槽包括至少一段凹形弧面，并且凹槽的槽宽为3.0mm-20mm；着色步骤包括采用热转印工艺对凹槽的内壁进行着色形成仿真美缝。
本发明中提供的仿真美缝的加工方法适用但不限于PVC板、聚丙烯(PP)板、ABS(Acrylonitrile-butdiene-styrene)板等，在PVC板中尤其适用于硬质片 材板，例如SPC板，也可以适用于PP板，SPC板和PP板的硬度较高，在热转印的时候板材不易变形，于其他实施例中还可以使用像LVT板、WPC板的半硬质片材塑胶板，但是LVT板、WPC板在热转印的时候容易变形。而且，使用木板的时候，倒角容易有倒刺，影响美观和影响着色层的附着力。
本发明中的着色步骤中着色的颜色包括但不限于灰色、黑色、白色、淡灰色，着色的颜色根据实际需要选择，其中灰色贴紧于水泥材质的颜色。
本发明中的凹槽的槽宽可以是3.8mm、4mm、5mm、10mm、8mm、15mm、13mm等等。
本领域的技术人员认为在将诸如SPC板的PVC板材拼接时，为了方便安装，板材和板材之间的缝隙不宜过大，如果板材质之间的缝隙过大的话，不仅会大大增加施工难度，而且需要大量的填缝剂去填充缝隙，成本大幅度增加。因此，而现有的板材的缝隙的缝宽都很小，缝隙的宽度均小于4.0mm，有的甚至小于3mm，而且为了加工方便，缝隙的形状都为V形槽，也就是说现有的板材的倒角均为平面倒角，并且平面倒角的宽度均小于2mm，有的甚至于小于1.5mm。但是本申请克服了本领域中固有的偏见，通过实施本申请中的仿真美缝的加工方法后，在板材的表面上设置了较宽的凹槽(槽宽为3.0mm-20mm)，并且通过转印在凹槽的内壁着色，而且通过设置将凹形弧面，其朝着板材的方向下凹，使得最终的凹槽在视觉上和瓷砖美缝相似的视觉效果。
再者，由于现有技术中的平面倒角宽度较小，如果在平面倒角上转印的话，转印的颜色很容易溢出平面倒角的位置，申请人还尝试在呈凸形弧面的凹槽上进行转印，转印的颜色也容易溢出，而本申请中设置凹形弧面的两端形成两个尖锐的锐角，转印的颜色不易溢出。
于本发明中，如果板材已经设有符合条件的凹槽，那倒角处理步骤可以省略。
于一种实施方式中，凹槽为呈凹型的圆弧形凹槽，圆弧形凹槽对应的圆心角是30°-60°，优选的，可以设置为45°、48°、40°、50°等等。圆弧形凹槽和板材的表面的夹角是15°-30°，优选的，可以设置为20°、25°、28°、18°等等，使得转印的颜色不易溢出。圆弧形凹槽的槽深是0.5mm-2mm，优选的，可以设置为0.8mm、1mm、1.5mm、1.2mm等等。于另一种实施方式中，凹槽包括一段凹形弧面及一段或至少两段平面，凹形弧面占整个凹槽的宽度的80％以上，有的实施方式中达到90以上，甚至于95％以上；当平面为一段时，凹形弧面的远离板材的侧边的一侧和平面连接，平面和板材的表面的夹角为是 15°-30°；当平面为至少两段时，凹形弧面的两侧分别和其中两段平面连接，平面和板材的表面的夹角为是15°-30°。
可选的，圆弧形凹槽的两侧沿和所述板材的表面的夹角的大小不同，也就是本申请中的圆弧形凹槽是不对称设置的，于一种实施方式中，靠近板材的侧边的夹角要小于远离侧边的那个夹角，有利于平滑过渡，但是于其他的实施方式中，靠近侧边的夹角也可以大于远离侧边的那个夹角。
可选的，将进行倒角处理的边沿定义为第一边沿，加工方法还包括将板材的表面的第二边沿进行倒斜角处理，第二边沿和第一边沿分别位于板材相对的两侧，斜角的角度和深度和凹槽的形状和尺寸相匹配以实现相邻拼接的板材的平滑连接。斜角的角度小于所述夹角，更进一步的，斜角的角度小于30°，斜度越小，斜角越浅，斜角也就越不明显，但是对应地，斜角的宽度越大。
更进一步的，斜角是平面斜角。斜角和圆弧形凹槽的设置均利于下文中提到的卡扣的扣接。
可选的，加工方法还包括第二倒角处理步骤，第二倒角处理步骤设于倒角处理步骤和着色步骤之间，第二倒角处理步骤包括：在圆弧形凹槽的和斜角相接的位置进行第二倒角得到用于和斜角平滑连接的过渡圆弧，以使斜角的宽度小于等于圆弧形凹槽的槽宽的1/3，斜角的宽度方向和圆弧形凹槽的槽宽的方向一致，于一些实施例中，斜角的宽度可以设置为小于等于圆弧形凹槽的槽宽的1/4，甚至是1/5，由于本发明中的斜角的宽度很小，大概为0.5mm-2mm，斜角的宽度和凹槽的槽宽的方向一致，或者本申请中的在肉眼观察时，很难观察到该斜角，因此通过过渡圆弧的设置，本发明中的斜角不需要进行额外的着色处理，因此本申请的板材只需要对其一半的边沿进行着色处理，便于加工。再者，过渡圆弧比圆弧形凹槽上翘，更进一步地防止转印的颜色溢出。
可选的，第一边沿和第二边沿互相平行并且有至少两对第一边沿和第二边沿，倒角处理步骤包括将板材的表面的相邻的至少两个第一边沿进行倒角处理以获得相邻设置的至少两个凹槽，第二边沿均不用进行着色处理，这里的凹槽呈直线型，利于流水线操作。于一种可行的实施方式中，第一边沿和第二边沿有两对，对应的，凹槽也有两个。于其他的可行的实施方式中，凹槽还可以是弧线型。
可选的，着色步骤在热转印机上进行，热转印机包括热压件、传送机构及色带收卷装置，传送机构用于传送板材，传送机构在凹槽的对应的位置设有金属材料制成的支撑板，以便滚轮的施力。板材的传送方向上对应设有热压件， 色带收卷装置用于将色带沿着传送方向平铺在板材的凹槽上；着色步骤包括热压件的调整步骤和热压步骤，热压件的调整步骤包括调整热压件的位置以使热压件对应于凹槽；热压步骤包括通过热压件的热压将平铺在凹槽上的色带的墨色层转印到圆弧形凹槽的内壁上，热压件的温度为150℃-380℃，作为可选的，热压件的温度可以是200℃、250℃、180℃、320℃、330℃、360℃、350℃等任意数值，根据色带的材料选定具体的热压件的加热温度。作为一种可行的实施方式，热转印机还包括除尘机构，在着色步骤之间通过除尘机构对板材进行除尘。在一些流水线操作过程中，热压件的调整步骤可以穿插在整个加工的流水线生产工艺中。热转印机还可以包括感应机构、主控机构，感应装置用于感应板材的位置，主控机构根据感应装置传输的信息控制滚轮的工作。
本发明中的凹槽和第一边沿的延伸方向一致，并且凹槽始终延伸在整个第一边沿上，也便于流水线操作。
可选的，热压件包括具有弹性的滚轮，滚轮的旋转的线速度范围为5m/min-30m/min，作为可选的，具有弹性的滚轮采用橡胶制成，滚轮的旋转的线速度和板材的传送速度相等或滚轮的旋转的线速度略小于板材的传送速度，色带收卷装置的速度和板材的传送速度相等。采用橡胶制成，不仅具有弹性而且不会对板材造成损伤。
可选的，热压步骤中热压件的热压有多道，其中的一个或多个热转印机包括多个滚轮，同一个热转印机中的所有滚轮沿着板材的移动方向均位于同一直线上，多道热压可以增加转印的着色层的附着力。
可选的，着色步骤还包括热压件的压力调整步骤，压力调整步骤位于热压步骤之前，压力调整步骤包括通过调节热压件至板材的高度的大小来调整热压件在下压时对板材的压力的大小，压力的大小至少要保证着色层具有良好的附着力。
可选的，热转印机至少为两个，作为举例的，热转印机为两个，分别为第一热转印机和第二热转印机，两个热转印机中的板材的传送方向分别和相邻的两个第一边沿的方向平行，两个热转印机中的传送机构相连，定义相邻设置的两个凹槽分别为第一凹槽和第二凹槽，着色步骤包括热压件的调整、第一热压机第二热压；热压件的调整包括调整两个热转印机的热压件的位置以使热压件分别对应于第一凹槽和第二凹槽；第一热压包括通过第一热转印机的热压件的热压将色带的墨色层转印到第一凹槽的内壁上；第二热压包括经过第一热压后的热压件被传送到第二热转印机上，第二热转印机的热压件的热压将色带的墨 色层转印到第二凹槽的内壁上；其中，第一热压和第二热压中的热压件的温度范围均为150℃-380℃，第一热压和第二热压中的热压件的温度均可以是200℃、250℃、180℃等任意数值。第一热压的温度和第二热压的温度可以相同，也可以不同。
可选的，加工方法还包括冲扣件步骤，冲扣件步骤和倒角处理步骤同时进行，或者冲扣件步骤设于倒角处理步骤之前，或者设于倒角处理步骤之后但在着色步骤之前，冲扣件步骤中得到的扣件用于相邻的板材的扣接，在圆弧形凹槽的内壁沿着板材的厚度方向延伸至板材的底面均为实心结构，使得板材不易变形。优选的，冲扣件步骤和所述倒角处理步骤同时进行。
可选的，板材的厚度不小于4.5mm，厚度太小的板材在热压的过程中容易变形或者断裂。
本发明还提供一种仿真板材，由任一如上所述的仿真美缝的加工方法涂覆后制备得到，仿真板材的表面的至少一个边沿设有凹槽，凹槽包括至少一段凹形弧面，并且凹槽的槽宽为3.0mm-20mm，凹槽的内壁上涂覆有着色层。
本发明还提供一种仿真板材组件，由多个相同的任一如上所述的仿真板材拼接得到，相接的仿真板材的板材之间以一个凹槽间隔开。
可选的，仿真板材为平行四边形，更进一步地，仿真板材为长方形甚至是正方形，仿真板材的相邻的两个第一边沿分别设有相邻的第一凹槽和第二凹槽，所有的仿真板材均相同，相接的仿真板材通过第一凹槽或第二凹槽间隔。于其他实施例中，仿真板材还可以为梯形、三角形、圆形等等任意的其他的形状。
综上，本发明克服了本领域中固有的偏见，通过实施本申请中的仿真美缝的加工方法后，在板材的表面上设置了较宽的凹槽(槽宽为3.0mm-20mm)，并且通过转印在凹槽的内壁着色，而且凹形弧面使得最终的凹槽在视觉上和瓷砖美缝相似的视觉效果。再者，本申请中设置的凹槽朝着板材的方向下凹，转印颜色不易溢出。
其次，使用本发明中的仿真美缝的加工方法制备得到的具有仿真美缝的仿真板材及由其拼接形成的仿真板材组件，具有和瓷砖、木板等的美缝相似的视觉效果，如果在板材上设置相应的花纹、图案，最终使得和瓷砖、木板等有相似的视觉效果。
附图说明
图1是本发明中的实施例一提供的加工方法的工艺流程图；
图2是本发明中的实施例一提供的进行倒角处理后和着色步骤后的具有仿真美缝的仿真板材的俯视图；
图3是本发明中的实施例一提供的经过倒角处理后的板材的侧视图；
图4是本发明中的实施例二提供的仿真板材的示意图；
图5是本发明中的实施例二提供的通过一种拼接方式拼接的仿真板材组件的示意图；
图6是本发明中的实施例二提供的通过另一种拼接方式拼接的仿真板材组件的示意图；
图7是本发明中的实施例三提供的仿真板材组的沿着圆弧形凹槽的径向截面图之一；
图8是本发明中的实施例三提供的仿真板材组的沿着圆弧形凹槽的径向截面图之二；
图9是本发明中的实施例四提供的仿真板材组的沿着圆弧形凹槽的径向截面图；
图10是本发明中的实施例提供的色带的层状结构的示意图；
图11是本发明中的实施例提供的滚轮的示意图之一；
图12是本发明中的实施例提供的滚轮的示意图之二。
具体实施方式
下面结合附图和实施例，对本发明的具体实施方式作进一步详细描述。以下实例用于说明本发明，但不用来限制本发明的范围。
本发明中的所有的范围均包括端点值。
本发明中的表面指的是板材的暴露于外界或者说是使用者可以看到的那一面，本发明中的底面指的是和表面相对的那一面。
本发明中的凹槽的槽宽方向和凹槽的延伸方向垂直。
实施例一
请参考图1，实施例一提供一种仿真美缝的加工方法，包括倒角处理步骤S01及着色步骤S02，倒角处理步骤S01包括将板材100的表面的其中一个边沿进行倒角处理以获得凹槽102，凹槽包括至少一段凹形弧面，并且凹槽的槽宽为3.0mm-20mm；着色步骤S02包括采用热转印工艺对凹槽的内壁进行着色形成仿真美缝101从而得到仿真板材，图2示出的是进行倒角处理后和着色步骤后的具有仿真美缝的仿真板材的俯视图，图3示出的是经过倒角处理后的板材的侧 视图，图2和图3中波浪线仅仅用作断裂处的边界线，对板材的形状不做任何限定。
更进一步地，本实施例中的着色步骤包括热压件的调整步骤和热压步骤，热压件的调整步骤包括调整热压件的位置以使热压件对应于凹槽；热压步骤包括通过热压件的热压将平铺在凹槽上的色带的墨色层转印到凹槽的内壁上。于其他实施例中，热压件的调整步骤可以省略。
本实施例中制备得到的仿真美缝在进行肉眼观察中可以发现其有不明显的不对称现象，但是尚在可以接受的范围内。
实施例二
在实施例一的基础上，实施二提供了形状为长方形的板材的仿真美缝的加工方法，并且提供的板材已经设有用于相邻的板材的拼接的扣件，该扣件设置的形状和位置使得凹槽底下的部分为实心结构，即凹槽的内壁沿着所述板材的厚度H方向延伸至所述板材的底面均为实心结构，本实施例中的板材的厚度为5mm。
本实施例中的加工方法包括倒角处理步骤和着色步骤，着色步骤包括热压件的调整、第一热压及第二热压。加工方法具体包括如下步骤：
倒角处理步骤：将板材的表面的相邻的两个第一边沿分别进行倒角处理以获得两个凹槽，即第一凹槽和第二凹槽，凹槽均为呈凹形的圆弧形凹槽，并且凹槽的槽宽都保持一致，本实施例中的凹槽的槽宽L1均为3.8mm；
热压件的调整：调整两个热转印机的热压件的位置以使热压件分别对应于第一凹槽和第二凹槽；
第一热压：通过第一热转印机的热压件的热压将色带的墨色层转印到第一凹槽的内壁上；
第二热压：经过第一热压后的热压件被传送到第二热转印机上，第二热转印机的热压件的热压将色带的墨色层转印到第二凹槽的内壁上；其中，第一热压和第二热压中的热压件的温度范围均为150℃-380℃。本实施例中的第一热压和第二热压均有两道。
如图4所示，本实施例还提供一种仿真板材，图中较粗的线条表示的是仿真美缝，由上述仿真美缝的加工方法涂覆后制备得到，将板材的表面的相邻的两个第一边沿分别进行倒角处理以获得两个凹槽，凹槽均为呈凹形的圆弧形凹 槽，并且凹槽的槽宽都保持一致，本实施例中的凹槽的槽宽为3.8mm，凹槽的内壁上涂覆有具有光泽的着色层。本实施例中制备得到的仿真美缝在进行肉眼观察中可以发现其有不明显的不对称现象，但是尚在可以接受的范围内。
如图5和图6所示，本发明还提供一种仿真板材组件，由多个相同的如上所述的仿真板材拼接得到，相接的仿真板材的板材之间以一个凹槽间隔开，并且附着力测试结构达到良好。
实施例三
在实施例二的基础上，实施三中的加工方法还包括倒斜角处理步骤，倒斜角处理步骤在倒角处理步骤和着色步骤之间，于其他实施例中，斜角处理步骤和倒角处理步骤可以同时进行。
倒斜角处理：第二边沿和第一边沿相对设置，斜角的设置有助于相邻板材的扣接。
制备得到的仿真板材组的沿着圆弧形凹槽的径向截面图如图7和图8所示，斜角500和圆弧形凹槽400之间没有平滑连接，本实施例中制备得到的仿真美缝在进行肉眼观察中可以发现其有不明显的不对称现象，但是尚在可以接受的范围内。
圆弧形凹槽对应的圆心角α的是48°，圆弧形凹槽和板材的表面的夹角θ的是30°圆弧形凹槽的槽深H1为0.8mm。
实施例四
在实施例三的基础上，实施四中的加工方法还包括第二倒角处理步骤，本实施例中的第二倒角处理步骤和倒角处理步骤同时进行，
第二倒角处理步骤包括：将圆弧形凹槽的斜角相接的位置进行第二倒角得到用于和斜角平滑连接的过渡圆弧401，本实施例中的过渡圆弧对应的圆心角也计入圆弧形凹槽对应的圆心角内，以使斜角的宽度L2小于等于圆弧形凹槽的槽宽的1/3，斜角的宽度方向和圆弧形凹槽的槽宽的方向一致，本实施例中的斜角的槽宽很小，为1.2mm，在本申请中的在肉眼观察时，很难观察到该斜角，因此通过过渡圆弧的设置，本发明中的斜角不需要进行额外的着色处理，因此本申请的板材只需要对其一半的边沿进行着色处理，便于加工。再者，过渡圆弧比圆弧形凹槽上翘，更进一步地防止转印的颜色溢出。
并且本实施例中的倒斜角处理中的斜角设置的角度β和深度H2和凹槽的形状和尺寸相匹配以实现相邻的板材的平滑连接。斜角的角度小于所述夹角，更进一步的，本实施例中的斜角的角度为25°，斜度越小，斜角越浅，斜角也就越不明显，但是对应地，斜角的宽度越大，就需要和过渡圆弧配合以实现将斜角的宽度和深度的尺寸设计合理化，最终实现斜角肉眼不可见或肉眼不明显可见。
制备得到的仿真板材组的沿着圆弧形凹槽的径向截面图如图9所示，图9中的虚线所示的是如果不进行第二倒角处理的圆弧形凹槽的界限，本实施例中的斜角和圆弧形凹槽之间平滑连接，本实施例中制备得到的仿真美缝在进行肉眼观察中具有和美缝相似的视觉效果，并且在着色的时候完全没有颜色的溢出。
实施例五
和实施例四不同的是，实施五提供了形状为长方形的板材的仿真美缝的加工方法，但是提供的板材没有设置用于相邻的板材的拼接的扣件600。因此在实施例二的加工方法的基础上，还包括冲扣件步骤，本实施例中的冲扣件步骤、倒角处理步骤、倒斜角处理均同时进行，但是于其他实施例中，冲扣件步骤、倒角处理步骤、倒斜角处理还可以分步进行，例如冲扣件步骤还可以设于倒角处理步骤之前，或者设于倒角处理步骤之后但在着色步骤之前。冲扣件步骤中得到的扣件用于相邻的板材的扣接，在圆弧形凹槽的内壁沿着板材的厚度方向延伸至板材的底面均为实心结构，使得板材不易变形。
斜角和圆弧形凹槽之间平滑连接，本实施例中制备得到的仿真美缝在进行肉眼观察中具有和美缝相似的视觉效果，并且在着色的时候完全没有颜色的溢出。
实施例六
和实施例四不同的是，实施六中提供的斜角的角度为75°，斜角的宽度很小，为0.3mm，同样地，斜角也不明显可见。
实施例七
和实施例四不同的是，实施七中提供的圆弧形凹槽的宽度为8mm，圆弧形凹槽对应的圆心角α的是60°，圆弧形凹槽和板材的表面的夹角θ的是20°, 圆弧形凹槽的槽深H1为0.8mm。斜角和圆弧形凹槽之间平滑连接，本实施例中制备得到的仿真美缝在进行肉眼观察中具有和美缝相似的视觉效果，并且在着色的时候完全没有颜色的溢出。
对比实施例一
对比实施例一和实施例二不同的地方在于，对比实施例一种的凹槽为平面斜角，但是最终得到的板材在美缝以外的位置有颜色溢出，完全没有仿美缝效果。
对比实施例二
对比实施例二和实施例二不同的地方在于，对比实施例一种的凹槽为向上凸的圆弧形凹槽，但是最终得到的板材在美缝以外的位置有颜色溢出，而且仿美缝效果不好。
对比实施例三
对比实施例三和实施例二不同的地方在于，扣件的位置有延伸在凹槽的下侧，采用喷涂的方式给凹槽着色，但是喷涂得到的着色层没有光泽，而且附着力不好。
本实施例中所有着色步骤均在热转印机上进行，热转印机包括热压件、传送机构及色带收卷装置，传送机构用于传送板材，板材的传送方向上对应设有热压件，色带收卷装置用于将色带沿着传送方向平铺在板材的凹槽上。作为另一种可行的实施方式中，热转印机还包括除尘机构，在着色步骤之间通过除尘机构对板材进行除尘。
本发明中所有的实施例和对比实施例中的热压件为具有弹性的滚轮，滚轮的旋转的线速度范围为5m/min-30m/min，如图10和图11所示，具有弹性的滚轮包括两部分，外圈和内圈，外圈32和板材接触的部分采用橡胶制成，内圈31用于安装并且和旋转轴连接的部分采用金属材料制成，滚轮如果有损耗或变形，可以重新打磨加工外圈，实现重复利用。滚轮的旋转的线速度和板材的传送速度相等或滚轮的旋转的线速度略小于板材的传送速度，色带收卷装置的速度和板材的传送速度相等。
滚轮的外圈的两侧的边沿上分别设有一个凸条321，凸条的形状和凹槽相对应，使得滚轮可以将色带的色转移层完全贴合在凹槽的内壁。于其他的实施方案中，滚轮的外圈的的凸台还可以仅为一条。
如图12所示，本发明中所有的实施例和对比实施例中的色带有四层结构，依次为：PET膜21和色转移层，色转移层包括UV层22、油墨层23、胶水层24。并且所有实施例和对比实施例中使用到的色带的宽度都略大于凹槽的展开后的内壁的长度。色转移层中可以含有聚乙烯蜡和EVA蜡。
除了实施例一中的热印机为一个以外，其他的各个实施例中的热转印机设有两个，分别为第一热转印机和第二热转印机，两个热转印机中的板材的传送方向分别和相邻的两个第一边沿的方向平行，两个热转印机中的传送机构相连，可以用于连续传送和生产。
本发明中对各个实施例和各个对比实施例中制备得到的仿真美缝的测量方法分为肉眼观察颜色溢出情况、肉眼观察光泽度、肉眼观察褶皱情况和附着力评估。
其中的附着力评估测试可以粗略地分为如下三个等级：
优秀：将胶带粘在仿真美缝上，并用手指按压划过一次，快速撕掉胶带后，着色层没有明显的掉落(掉落面积占粘贴总面积的1％以下，即基本不掉)。
良好：将胶带粘在仿真美缝上，并用手指按压划过一次，缓慢撕掉胶带后，着色层没有明显的掉落(掉落面积占粘贴总面积的30％以下)。
不良：用手指划过仿真美缝的表面，涂层有明显掉落或者将胶带粘在仿真美缝上，并用手指按压划过一次，缓慢撕掉胶带后，着色层明显掉落(掉落面积大于粘贴总面积的30％)。
所有实施例中得到的仿真美缝均具有光泽，并且转印的着色层没有明显的褶皱，再者也没有明显的颜色溢出现象。
本领域技术人员应理解的是，在本发明的揭露中，术语“上”、“下”、“前”、“后”、“左”、“右”、“竖直”、“水平”、“顶”、“底”“内”、“外”等指示的方位或位置关系是基于附图所示的方位或位置关系，其仅是为了便于描述本发明和简化描述，而不是指示或暗示所指的装置或元件必须具有特定的方位、以特定的方位构造和操作，因此上述术语不能理解为对发明的限制。
虽然本发明已由较佳实施例揭露如上，然而并非用以限定本发明，任何熟知此技艺者，在不脱离本发明的精神和范围内，可作些许的更动与润饰，因此本发明的保护范围当视权利要求书所要求保护为准。

Claims (15)

  1. 一种仿真美缝的加工方法，其特征在于，包括：
    倒角处理步骤：将板材的表面的至少一个边沿进行倒角处理以获得凹槽，所述凹槽包括至少一段凹形弧面，所述凹槽的槽宽为3.0mm-20mm；及
    着色步骤：采用热转印工艺对所述凹槽的内壁进行着色形成所述仿真美缝。
  2. 如权利要求1所述的仿真美缝的加工方法，其特征在于，所述凹槽为成凹形的圆弧形凹槽，所述圆弧形凹槽对应的圆心角为30°-60°，所述圆弧形凹槽的槽深是0.5mm-2mm，所述圆弧形凹槽和板材的表面的夹角是15°-30°。
  3. 如权利要求2所述的仿真美缝的加工方法，其特征在于，圆弧形凹槽的两侧沿和所述板材的表面的夹角的大小不同。
  4. 如权利要求2所述的仿真美缝的加工方法，其特征在于，将进行倒角处理的边沿定义为第一边沿，所述加工方法还包括将所述板材的表面的第二边沿进行倒斜角处理，所述第二边沿和所述第一边沿分别位于板材相对的两侧，所述倒斜角处理得到的斜角的角度和所述凹槽的形状和尺寸相匹配以实现相邻拼接的板材的平滑连接。
  5. 如权利要求4所述的仿真美缝的加工方法，其特征在于，所述斜角的角度小于所述夹角。
  6. 如权利要求5所述的仿真美缝的加工方法，其特征在于，所述加工方法还包括第二倒角处理步骤，所述第二倒角处理步骤设于所述倒角处理步骤和所述着色步骤之间，所述第二倒角处理步骤包括：在所述凹槽的和所述斜角相接的位置进行第二倒角得到用于和所述斜角平滑连接的过渡圆弧，以使所述斜角的宽度小于等于所述凹槽的槽宽的1/3。
  7. 如权利要求4或5或6所述的仿真美缝的加工方法，其特征在于，所述第一边沿和第二边沿互相平行并且至少有两对第一边沿和第二边沿，所述倒角处理步骤包括将板材的表面的相邻的至少两个第一边沿进行倒角处理以获得相邻设置的至少两个凹槽。
  8. 如权利要求1至6中任一所述的仿真美缝的加工方法，其特征在于，所述着色步骤在热转印机上进行，所述热转印机包括热压件、传送机构及色带收卷装置，所述传送机构用于传送板材，所述板材的传送方向上对应设有所述热压件，所述色带收卷装置用于将色带沿着所述传送方向平铺在所述板材的凹槽上；所述着色步骤包括：
    热压件的调整步骤：调整热压件的位置以使所述热压件对应于所述凹槽；
    热压步骤：通过热压件的热压将平铺在凹槽上的色带的墨色层转印到凹槽的内壁上，所述热压件的温度为150℃-380℃。
  9. 如权利要求8所述的仿真美缝的加工方法，其特征在于，所述热压件包括具有弹性的滚轮，所述滚轮的旋转的线速度范围为5m/min-30m/min，所述滚轮的旋转的线速度和所述板材的传送速度相等或所述滚轮的旋转的线速度略小于所述板材的传送速度，所述色带收卷装置的速度和所述板材的传送速度相等。
  10. 如权利要求8所述的仿真美缝的加工方法，其特征在于，所述着色步骤还包括热压件的压力调整步骤，所述压力调整步骤位于所述热压步骤之前，所述压力调整步骤包括通过调节所述热压件至所述板材的高度的大小来调整所述热压件在下压时对所述板材的压力的大小。
  11. 如权利要求7所述的仿真美缝的加工方法，其特征在于，热转印机至少为两个，包括第一热转印机和第二热转印机，第一热转印机和第二热转印机中的板材的传送方向分别和相邻的两个第一边沿的方向平行，第一热转印机和第二热转印机的传送机构相连，定义相邻设置的其中两个凹槽分别为第一凹槽和第二凹槽，所述着色步骤包括：
    热压件的调整：调整两个热转印机的热压件的位置以使热压件分别对应于第一凹槽和第二凹槽；
    第一热压：通过第一热转印机的热压件的热压将色带的墨色层转印到第一凹槽的内壁上；
    第二热压：经过第一热压后的热压件被传送到第二热转印机上，第二热转印机的热压件的热压将色带的墨色层转印到第二凹槽的内壁上；
    其中，所述第一热压和所述第二热压中的热压件的温度范围均为150℃-380℃。
  12. 如权利要求1所述的仿真美缝的加工方法，其特征在于，所述加工方法还包括冲扣件步骤，所述冲扣件步骤和所述倒角处理步骤同时进行，或者所述冲扣件步骤设于所述倒角处理步骤之前，或者设于所述倒角处理步骤之后但在所述着色步骤之前，所述冲扣件步骤中得到的扣件用于相邻的板材的扣接，在凹槽的内壁沿着所述板材的厚度方向延伸至所述板材的底面均为实心结构。
  13. 如权利要求1所述的仿真美缝的加工方法，其特征在于，所述板材选自SPC板材、PP板中的任意一种或多种，所述板材的厚度不小于4.5mm。
  14. 一种仿真板材，由权利要求1至13中任一所述的仿真美缝的加工方法涂覆后制备得到，其特征在于，所述仿真板材的表面的至少一个边沿设有凹槽，所述凹槽包括至少一段凹形弧面，并且所述凹槽的槽宽为3.0mm-20mm，所述凹槽的内壁上涂覆有着色层。
  15. 一种仿真板材组件，其特征在于，由多个相同的如权利要求14中的仿真板材拼接得到，相接的仿真板材之间以一个凹槽间隔开。
PCT/CN2021/096664 2021-04-29 2021-05-28 仿真美缝的加工方法、仿真板材及仿真板材组 WO2022227174A1 (zh)

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