CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority of Chinese Patent Application No. 202011642281.2, filed on Dec. 31, 2020, the contents of which are hereby incorporated by reference.

TECHNICAL FIELD

The present disclosure relates to decorative board manufacturing, and more specifically, relates to a composite decorative board and a manufacturing method thereof.

BACKGROUND

At present, people usually use ceramic tiles or stone plastic composite boards (e.g., wooden multi-layer boards, high density boards, or inorganic boards) as decoration materials. However, the ceramic tiles have relatively weak impact resistances, and are fragile. Weights of the ceramic tiles are relatively large, which have a greater impact on high-rise buildings. Besides, most stone-plastic boards on the market need to be manufactured in a compound manner using glue and hot-pressing. A high-gloss effect of a surface of the stone-plastic board may be compressed using a mirror steel board. On one hand, the manufacturing efficiency and the production yield of the stone plastic board may be low, and the labor cost may be high; on the other hand, since a decorative surface and a substrate board of the stone plastic board are combined using glue, it is not environmentally friendly and is liable to delaminate, and a structure of the product is unstable.

Therefore, it is necessary to provide a composite decorative board with a high manufacture efficiency, being environmentally friendly, and having no formaldehyde, a lower density than the ceramic tiles, a good temperature resistance, and a good stability.

SUMMARY

One of the embodiments of the present disclosure provides a composite decorative board having a multi-layer structure. The decorative board may include a substrate layer. The substrate layer may include at least one first structural layer and at least one second structural layer. The second structural layer may be disposed on the first structural layer. The first structural layer may be an elastic layer. A component of the first structural layer may include a plasticizer. The second structural layer may be a rigid layer.

In some embodiments, as for 323.45 parts by weight of the first structural layer, the first structural layer may include 10-20 parts by weight of the plasticizer.

In some embodiments, the plasticizer may include epoxy groups.

In some embodiments, the plasticizer may include at least one of epoxy linseed oil or epoxy soybean oil.

In some embodiments, the components of the first structural layer may further include polyvinyl chloride, at least one inorganic filler, at least one lubricant, and at least one stabilizer.

In some embodiments, the components of the first structural layer may further include at least one colorant. The at least one inorganic filler may include calcium carbonate. The at least one lubricant may include polyethylene wax.

In some embodiments, the components of the first structural layer may include 90-100 parts by weight of polyvinyl chloride, 200-250 parts by weight of calcium carbonate, 0.1-0.3 parts by weight of polyethylene wax, 2-4 parts by weight of a stabilizer, 10-20 parts by weight of the plasticizer, and 0.1-0.4 parts by weight of at least one colorant.

In some embodiments, a thickness of the first structural layer may be 1.0-1.5 millimeters.

In some embodiments, the components of the second structural layer may include 90-110 parts by weight of polyvinyl chloride, 300-400 parts by weight of calcium carbonate, 1.0-1.6 parts by weight of polyethylene wax, 5-7 parts by weight of a stabilizer, 1.1-1.7 parts by weight of stearic acid, and 5-7 parts by weight of a forming agent of acrylate resin coordinating a metal ion.

In some embodiments, the components of the second structural layer may include 100 parts by weight of the polyvinyl chloride, 350 parts by weight of the calcium carbonate, 1.3 parts by weight of the polyethylene wax, 6 parts by weight of the stabilizer, 1.4 parts by weight of the stearic acid, and 6 parts by weight of the forming agent of acrylate resin coordination the metal ion.

In some embodiments, the thickness of the second structural layer may be 3.0-6.5 millimeters.

In some embodiments, the composite decorative board may further include an ultraviolet (UV) coating layer disposed on the second structural layer. The UV coating layer may at least include one of a primer coating layer and a surface coating layer.

In some embodiments, the primer coating layer may have a mass per unit area of 10-15 g/m2. The surface coating layer may have a mass per unit area of 60-70 g/m2.

In some embodiments, the components of the primer coating layer may include 25-50 parts by weight of hyperbranched polyester polyfunctional acrylic resin, 20-30 parts by weight of modified epoxy acrylic resin, 30-40 parts by weight of hydroxyethyl methacrylate, 0.8-2.0 parts by weight of 1-hydroxycyclohexane phenyl ketone, and 1-3.0 parts by weight of fumed silica.

In some embodiments, the components of the surface coating layer may include 25-50 parts by weight of hyperbranched polyester polyfunctional acrylic resin, 20-30 parts by weight of modified epoxy acrylic resin, 30-40 parts by weight of hydroxyethyl methacrylate, 0.8-2.0 parts by weight of 1-hydroxycyclohexane phenyl ketone, and 1-3.0 parts by weight of fumed silica.

One of the embodiments of the present disclosure provides a method for manufacturing a composite decorative board. The method may include forming the substrate layer by extruding raw materials of the first structural layer and the second structural layer through a coextrusion extruder; obtaining a semi-manufactured board by rolling the substrate layer, a printed decorative layer, and a wear-resistant layer through one-step forming; forming a prime coating layer on the semi-manufactured board through a first roller coating procedure, the roller coating procedure including a UV semi-curing operation; forming a surface coating layer on the prime coating layer through a second roller coating procedure; performing an infrared self-leveling treatment on the semi-manufactured board processed by the first roller coating procedure and the second roller coating procedure; and forming a UV coating layer by performing a film pressing solidification on a surface cured film disposed on the semi-manufactured board processed by the infrared self-leveling treatment.

In some embodiments, the forming the UV coating layer by performing the film pressing solidification on the surface cured film disposed on the semi-manufactured board processed by the infrared self-leveling treatment may include forming a medium/high gloss UV coating layer in the air by performing an intermolecular solidification between the surface cured film and the semi-manufactured board processed by the infrared self-leveling treatment using a UV ultraviolet lamp, wherein a polyethylene terephthalate (PET) polyester film may be used as the surface cured film; or forming a skin-feeling UV coating layer under an inert gas by performing an intermolecular automated ordering between the surface cured film and the semi-manufactured board processed by the infrared self-leveling treatment using a UV excimer lamp, wherein a macromolecule polyester skin-feeling film may be used as the surface cured film.

In some embodiments, the method may further include pretreating raw materials of the first structural layer before the raw materials of the first structural layer and the second structural layer is extruded through the coextrusion extruder. The pretreating the raw materials of the first structural layer may include obtaining a first ingredient by stirring and heating the raw materials of the first structural layer to a first preset temperature, mixing at least one inorganic filler, at least one lubricant, and at least one stabilizer with the raw materials of the first structural layer, stirring and heating the mixture to a second preset temperature, and cooling the mixture from the second preset temperature to a third preset temperature. Components of the raw materials of the first structural layer may include polyvinyl chloride and a plasticizer.

In some embodiments, the components of raw materials of the first structural layer may include calcium carbonate, polyethylene wax, at least one stabilizer, and at least one colorant.

In some embodiments, the method may further include pretreating raw materials of the second structural layer before the raw materials of the first structural layer and the second structural layer is extruded through the coextrusion extruder. The pretreating the raw materials of the second structural layer may include obtain a second ingredient by stirring and heating the raw materials of the second structural layer to a fourth preset temperature, and cooling the raw materials of the second structural layer from the fourth preset temperature to a fifth preset temperature.

