CA2678557A1 - Method of manufacturing coating elements and production installation relating thereto - Google Patents
Method of manufacturing coating elements and production installation relating thereto Download PDFInfo
- Publication number
- CA2678557A1 CA2678557A1 CA2678557A CA2678557A CA2678557A1 CA 2678557 A1 CA2678557 A1 CA 2678557A1 CA 2678557 A CA2678557 A CA 2678557A CA 2678557 A CA2678557 A CA 2678557A CA 2678557 A1 CA2678557 A1 CA 2678557A1
- Authority
- CA
- Canada
- Prior art keywords
- fibre material
- paper web
- resin
- printing
- paper
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 59
- 239000011248 coating agent Substances 0.000 title claims abstract description 55
- 238000000576 coating method Methods 0.000 title claims abstract description 55
- 238000009434 installation Methods 0.000 title claims abstract description 40
- 239000000463 material Substances 0.000 claims abstract description 57
- 239000000835 fiber Substances 0.000 claims abstract description 54
- 238000000034 method Methods 0.000 claims abstract description 33
- 229920003002 synthetic resin Polymers 0.000 claims abstract description 21
- 239000000057 synthetic resin Substances 0.000 claims abstract description 21
- 229920005989 resin Polymers 0.000 claims abstract description 20
- 239000011347 resin Substances 0.000 claims abstract description 20
- 229920000877 Melamine resin Polymers 0.000 claims abstract description 15
- 239000004640 Melamine resin Substances 0.000 claims abstract description 14
- 238000005034 decoration Methods 0.000 claims abstract description 8
- 238000001035 drying Methods 0.000 claims description 12
- 238000005470 impregnation Methods 0.000 claims description 9
- 238000005299 abrasion Methods 0.000 claims description 5
- 229910052593 corundum Inorganic materials 0.000 claims description 5
- 239000010431 corundum Substances 0.000 claims description 5
- 229920002678 cellulose Polymers 0.000 claims description 3
- 239000001913 cellulose Substances 0.000 claims description 3
- 238000007603 infrared drying Methods 0.000 claims description 3
- 230000005855 radiation Effects 0.000 claims description 3
- 239000000126 substance Substances 0.000 claims description 3
- 238000003475 lamination Methods 0.000 claims description 2
- 239000000123 paper Substances 0.000 description 65
- 239000002023 wood Substances 0.000 description 6
- 239000002131 composite material Substances 0.000 description 5
- 239000002655 kraft paper Substances 0.000 description 3
- 239000002245 particle Substances 0.000 description 3
- 239000004033 plastic Substances 0.000 description 3
- 238000005253 cladding Methods 0.000 description 2
- 239000005011 phenolic resin Substances 0.000 description 2
- 238000004026 adhesive bonding Methods 0.000 description 1
- 238000007605 air drying Methods 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 230000018109 developmental process Effects 0.000 description 1
- 230000009977 dual effect Effects 0.000 description 1
- 238000011156 evaluation Methods 0.000 description 1
- -1 for example Polymers 0.000 description 1
- 238000007654 immersion Methods 0.000 description 1
- 238000010030 laminating Methods 0.000 description 1
- JDSHMPZPIAZGSV-UHFFFAOYSA-N melamine Chemical compound NC1=NC(N)=NC(N)=N1 JDSHMPZPIAZGSV-UHFFFAOYSA-N 0.000 description 1
- 230000003287 optical effect Effects 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 229920006395 saturated elastomer Polymers 0.000 description 1
- 239000004575 stone Substances 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
Classifications
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H27/00—Special paper not otherwise provided for, e.g. made by multi-step processes
- D21H27/18—Paper- or board-based structures for surface covering
- D21H27/22—Structures being applied on the surface by special manufacturing processes, e.g. in presses
- D21H27/26—Structures being applied on the surface by special manufacturing processes, e.g. in presses characterised by the overlay sheet or the top layers of the structures
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H17/00—Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
- D21H17/20—Macromolecular organic compounds
- D21H17/33—Synthetic macromolecular compounds
- D21H17/46—Synthetic macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
- D21H17/47—Condensation polymers of aldehydes or ketones
- D21H17/49—Condensation polymers of aldehydes or ketones with compounds containing hydrogen bound to nitrogen
- D21H17/51—Triazines, e.g. melamine
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H19/00—Coated paper; Coating material
- D21H19/36—Coatings with pigments
- D21H19/44—Coatings with pigments characterised by the other ingredients, e.g. the binder or dispersing agent
- D21H19/62—Macromolecular organic compounds or oligomers thereof obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
Landscapes
- Laminated Bodies (AREA)
Abstract
In order to further develop a method of producing at least one coating element, more particularly at least one decorative layer suitable for coating at least one carrier board (60), whereby - through unrolling raw fibre material or raw paper, more particularly raw decorative paper, at least one fibre material or paper web (50) is stretched out and - the stretched out fibre material or paper web (50) is at least partially printed with colour and/or at least one patter or decoration, as well as production installation (100) relating thereto, in such a way that the coating element can be efficiently produced while reliably avoiding kinks, cracks or changes in shape of the printed fibre material or paper web, it is proposed that after printing the stretched out fibre material or paper web (50) is at least in parts - impregnated with at last one resin, more particularly at least one animoplastic and/or thermally hardening synthetic resin, for example melamine resin, and/or - coated with a layer containing at least one resin, more particularly an aminoplastic and/or thermally hardening synthetic resin, for example melamine resin.
Description
Method of manufacturing coating elements and production installation relating thereto Technical field The present invention relates to a method in accordance with the introductory section of claim 1.
The present invention also relates to a production installation in accordance with the introductory section of claim 5.
State of the art Laminate is a layered pressed material formed by pressing, adhering and/or gluing together at least two layers of the same and/or different material.
A laminate that is used, for example, as a floor, as a wall or ceiling cladding, as a work top or for manufacturing furniture has at least one carrier board which is coated with at least one coating element, more particularly with at least one decorative layer or decorative paper with thermally hardening resin.
The carrier board is usually a composite wood board, such as a fibre board, for example a high-density fibreboard (HDF)or a medium-density fibreboard (MDF) or a particle board, or a composite wood board made of orientated micro veneers, known as an O[riented]S[trand]B[oard]
Decisive for the optical appearance of the laminate is the decorative layer which is applied to the upper side of the carrier board. The decorative paper of the decorative layer can be printed with a colour and/or a pattern or decoration, for example a wood or stone reproduction.
The present invention also relates to a production installation in accordance with the introductory section of claim 5.
State of the art Laminate is a layered pressed material formed by pressing, adhering and/or gluing together at least two layers of the same and/or different material.
A laminate that is used, for example, as a floor, as a wall or ceiling cladding, as a work top or for manufacturing furniture has at least one carrier board which is coated with at least one coating element, more particularly with at least one decorative layer or decorative paper with thermally hardening resin.
The carrier board is usually a composite wood board, such as a fibre board, for example a high-density fibreboard (HDF)or a medium-density fibreboard (MDF) or a particle board, or a composite wood board made of orientated micro veneers, known as an O[riented]S[trand]B[oard]
Decisive for the optical appearance of the laminate is the decorative layer which is applied to the upper side of the carrier board. The decorative paper of the decorative layer can be printed with a colour and/or a pattern or decoration, for example a wood or stone reproduction.
To improve the wear resistance of the laminate the decorative paper is usually impregnated with thermally-hardening synthetic resin, for example melamine resin, and/or coated with an abrasion-resistant layer, known as the overlay.
The overlay consists of thermally-hardening synthetic resin, for example melamine resin. For improved resin uptake the overlay can also consist of fibrous, more particularly cellulose-containing, material. In order to improve its abrasion resistance this fibrous synthetic resin layer can also be provided with abrasion-resistant and/or abrasive substance such as corundum particles for instance. The overlay can for example consist of two transparent melamine resin-impregnated papers, between which a corundum layers is included. Corundum-filled overlays are also usual.
On the side of the coating element facing the carrier board a core or carrier paper layer of several papers impregnated with thermally hardeningsynthetic resin, for example phenol resin, can be arranged. This optional paper layer, in which kraft paper is preferably used as the paper, provides the covering layers with additional hardness and impact resistance and improves its standing ability.
To improve the dimensional stability of the laminate element, the underside of the carrier board can be pressed with a backer sheet, for example a veneer or another layer impregnated with a thermally hardening synthetic resin.
In the manufacturing of laminate a distinction is made between a single stage and dual stage manufacturing process. In the single stage manufacturing process the various layers, i.e. the decorative layer of decorative paper and thermally hardening synthetic resins, which can, for example, be applied in the form of an overlay on the decorative paper, the carrier board and the optional backer sheet are pressed together in one operation to form a direct pressure laminate (DPL).
In the dual-stage method on the other hand, in a first stage a coating element is produced from the decorative paper and the thermally-hardening resin which, for example, can be applied to the decorative paper in the form of an overlay, and the optional core or carrier paper layer. In a second stage the coating element is then pressed with the carrier board. These laminate manufacturing methods are described in DIN standards DIN EN 14322, DIN EN 438-2 and DIN EN 13329. With regard to the technical background of laminate manufacturing reference is made to document WO 2007/079547 Al.
In the known laminate manufacturing processes the decorative layer of decorative paper and thermally-hardening synthetic resin is produced in two working stages on two separate production installations. First of all the decorative paper is printed on a first production installation, whereby the printing using takes place using the intaglio process. The printed decorative paper is then rolled up and transported to a second installation for impregnation or coating with thermally hardening synthetic resin. At the second production installation the printed paper is then impregnated with the thermally hardening synthetic resin or is coated with the overlay.
However, producing the decorative layer on two separate production installations and/or in two separate production stages is not very efficient as the raw decorative paper has to be transported to two different production installations and positioned in each one of these. In the first production installation a paper web of raw paper is stretched out for printing and in the second production installation a second paper web of printed paper is stretched out for impregnation or coating of the paper.
This method of product is time and therefore cost-intensive. Two separate production installations also require a relatively large amount of space.
The overlay consists of thermally-hardening synthetic resin, for example melamine resin. For improved resin uptake the overlay can also consist of fibrous, more particularly cellulose-containing, material. In order to improve its abrasion resistance this fibrous synthetic resin layer can also be provided with abrasion-resistant and/or abrasive substance such as corundum particles for instance. The overlay can for example consist of two transparent melamine resin-impregnated papers, between which a corundum layers is included. Corundum-filled overlays are also usual.
On the side of the coating element facing the carrier board a core or carrier paper layer of several papers impregnated with thermally hardeningsynthetic resin, for example phenol resin, can be arranged. This optional paper layer, in which kraft paper is preferably used as the paper, provides the covering layers with additional hardness and impact resistance and improves its standing ability.
To improve the dimensional stability of the laminate element, the underside of the carrier board can be pressed with a backer sheet, for example a veneer or another layer impregnated with a thermally hardening synthetic resin.
In the manufacturing of laminate a distinction is made between a single stage and dual stage manufacturing process. In the single stage manufacturing process the various layers, i.e. the decorative layer of decorative paper and thermally hardening synthetic resins, which can, for example, be applied in the form of an overlay on the decorative paper, the carrier board and the optional backer sheet are pressed together in one operation to form a direct pressure laminate (DPL).
In the dual-stage method on the other hand, in a first stage a coating element is produced from the decorative paper and the thermally-hardening resin which, for example, can be applied to the decorative paper in the form of an overlay, and the optional core or carrier paper layer. In a second stage the coating element is then pressed with the carrier board. These laminate manufacturing methods are described in DIN standards DIN EN 14322, DIN EN 438-2 and DIN EN 13329. With regard to the technical background of laminate manufacturing reference is made to document WO 2007/079547 Al.
In the known laminate manufacturing processes the decorative layer of decorative paper and thermally-hardening synthetic resin is produced in two working stages on two separate production installations. First of all the decorative paper is printed on a first production installation, whereby the printing using takes place using the intaglio process. The printed decorative paper is then rolled up and transported to a second installation for impregnation or coating with thermally hardening synthetic resin. At the second production installation the printed paper is then impregnated with the thermally hardening synthetic resin or is coated with the overlay.
However, producing the decorative layer on two separate production installations and/or in two separate production stages is not very efficient as the raw decorative paper has to be transported to two different production installations and positioned in each one of these. In the first production installation a paper web of raw paper is stretched out for printing and in the second production installation a second paper web of printed paper is stretched out for impregnation or coating of the paper.
This method of product is time and therefore cost-intensive. Two separate production installations also require a relatively large amount of space.
Another drawback is that stretching out the paper web twice can lead to a change in the shape of the decorative paper and thereby deformation or distortion of the printed pattern as wall as to kinking and/or tearing of the decorative paper.
In document DE 600 15 603 T2 it is proposed, in order to avoid match imprecisions of the pattern of a laminate floor, to print this pattern directly onto the carrier board, thus for example directly onto the composite wood board by means of a digital printer. However, the drawback of this is that the surface of the carrier board has to be treated before printing, for example primed and/or ground. Also, in the case of the laminate element in accordance with document DE 600 15 603 T2 only transparent layers can be applied to the carrier board. For example, it is not possible to apply a core or carrier paper layer of kraft pulp to the carrier board.
Explanation of the present invention: objective, solution, advantages On the basis of the aforementioned disadvantages and inadequacies, as well as an evaluation of the described state of the art, the objective of the present invention is to further develop a method of the type set out in the introduction as well as a production installation of the type set out in the introduction so that the coating element can be efficiently manufactured, while reliably avoiding kinks, tears or changes in the shape of the printed fibre material or paper.
This objective is achieved by means of a method with the features set out in clam 1 as well as a production installation with the features set out in claim 5. Advantageous embodiments and expedient further developments of the present invention are characterised in the relevant sub-claims.
The present invention is fundamentally based on designing a series or in-line production installation, such an production line, in which the fibre material or paper is printed in a first stage and then immediately further processed by means of impregnation and/or coating. In accordance with the present invention the supplied fibre material or paper is printed in one production stage and then impregnated and/or coated in the same production stage.
According to the invention, in order to produce at least one coating element, more particularly for producing a decorative coating made of fibre material and resin, more particularly decorative paper and amino-plastic and or thermally hardening synthetic resin for coating at least one carrier board, at least one fibre material or paper web is initially stretched out by unrolling raw fibre material or raw paper, more particularly raw decorative paper. This stretched fibre material or paper web is at least partially printed with colour and/or with at least one pattern or decoration.
The stretched out and printed fibre material or paper web is then at least in parts - impregnated with at least one resin with at least one aminoplastic and/or thermally hardening synthetic resin, for example, melamine resin and/or - coated with a layer containing at least one resin, more particularly at least one aminoplastic and/or thermally hardening synthetic-resin, for example melamine resin, for example with a so-called overlay.
Combining printing and impregnation and/or coating in one production installation or one machine can be achieved by arranging at least one impregnating and/or coating device in series or in ine with at least one printing device. For example, the printing device can be arranged between at least one unrolling device for unrolling the fibre material or paper web, and a first immersion bath, or a first coating device of the impregnating and/or coating device. The unrolling device, printing device and/or coating device are preferably arranged in series, for example on at least one production band or production line, such as on at least one impregnating channel.
In accordance with an advantageous embodiment of the present invention the production installation has the components of a conventional impregnation and/or coating installation. However, these components are arranged so that the stretched out fibre material or paper web can be printed as well as impregnated and/or coated.
The fibre material or paper web can be printed by intaglio printing or by means of digital printing. Using the digital printing method is particularly advantageous as a digital printing device requires little space and can thus be simply integrated into a conventional impregnation machine.
Furthermore, a digital printing device or digital printer does not require cost-intensive printing plates. Other advantages of a digital printing system compared with intaglio printing are the lower investment costs as well as the possibility of simpler and more cost-effective decoration changing. In addition, with a digital printing system raw material storage costs can be reduced as a large number of decorations does not have to be kept in stock.
In accordance with an advantageous embodiment of the present invention the fibre material or paper web is printed by at least one digital printing device. This digital printing device exhibits the properties required for printing the fibre material or paper web and is preferably designed to essentially print the entire width of the fibre material or paper web.
Advantageously the digital printer device is designed to dry the printed fibre material or paper web at least in parts. Drying of the fibre material or paper web can take place by means of air and/or ultra-violet radiation and/or using the method of near infra-red drying. In addition to pure air drying other drying methods, such as UV drying and NIR drying can be used.
Due to its comparatively low printing speed an advantageous embodiment of the printer device has a comparatively short drying section, a few metres in length for example.
After passing through the printing device or printer the known impregnation and/or coating procedure can continue unchanged. For example, the stretched out fibre material or paper web with at least one resin, more particularly at least one aminoplastic and/or thermally hardening synthetic resin, for example melamine resin, can be saturated/impregnated and after saturation or impregnation with - at least one resin, more particularly at least one aminoplastic and/or thermally hardening synthetic resin, for example melamine resin, and/or - fibre material, more particularly cellulose, and/or - provided with a least one layer containing an abrasion-resistant substance, more particularly corundum.
Furthermore, the stretched out fibre material or paper web can, more particularly on its side facing away from the layer with resin, be coated with a core or carrier paper layer, whereby the core or carrier paper layer has at least one fibre material, more particularly paper, for example kraft paper, impregnated with a thermally-hardening synthetic resin, for example phenol resin.
The present invention also relates to a method of producing laminate, for example at least one laminate floor element, at least one laminate work top, a least one wall or ceiling cladding element of a laminate or at least one laminate furniture element, as well an installation relating thereto. In accordance with the invention, to produce laminate at least one coating element is produced by way of a method in accordance with the above type and - then applied to at least one carrier board, more particularly glued and/or stuck and/or pressed to it.
According to an advantageous further embodiment of the method according to the invention for producing a coating element as well as the production installation according to the invention, the stretched out fibre material or paper web of the coating element can also immediately, i.e. in the same production stage, be applied to the carrier board, for example a composite wood board, such as an MDF, HDF, OSB or particle board, or to a plastic board.
In addition, on its side facing away from the coating element, the carrier board can in the same production stage also be coated with at least one backer sheet, for example with at least one veneer and/or with at least one further layer with a thermally-hardening resin. The coating element can be laminated onto the carrier board by means of single-stage or dual-stage process. From the coating element produced in accordance with the invention D[irect]P[ressure]L[aminat], H[igh]P[ressure]L[aminat] as well as C[ontinuous]P[ressure]L[aminat] and also L[ow]P[ressure]L[aminat] can be produced.
The present invention finally relates to the use of a method for producing at least one coating element in accordance with the manner set out above and/or at least one production installation of the above-described type for the line or series production of printed, impregnated and/or coated decorative paper and/or for the line or series production of laminate, more particularly by means of a method for production of a laminate of the above-described type and/or by means of at least one device for producing laminate in accordance with type described above.
Brief description of the drawings As has already been stated, there are various possibilities of advantageously embodying and further developing the teaching of the present invention. With regard to this, reference is made on the one hand to the claims subordinate to claim 1 and to claim 5, and on the other hand further embodiments, feature and advantages of the present invention are explained in more detail below with the aid of the example of embodiment illustrated in figure 1.
Fig. 1 shows a schematic view of a first example of embodiment of a device in accordance with the present invention which operates in accordance with the method of producing or finishing laminate according to the present invention.
Best way of implementing the present invention In the first example of embodiment of the present invention illustrated in figure 1, an installation 200, more particularly a production line, for producing laminate is shown which operates in accordance with the present invention and has several functional components, namely - an example of embodiment of a production installation 100 for producing at least one coating element in accordance with the present invention, whereby the production installation 100 operates in accordance with the method of producing at least one coating element according to the present invention and - a laminating device 210 for applying the coating element, more particularly the stretched out, printed, impregnated and/or coated fibre material or paper web 50 to a carrier board 60.
The production installation 100 is designed for the production of a decorative layer suitable for coating the carrier board 60, whereby the decorative layer comprises at least one printed decorative paper and thermally-hardening synthetic resin.
For this purpose the production installation 100 has an unrolling device 10 designed for stretching out a fibre material or paper web 50 by means of unrolling raw fibre material or raw paper, more particularly raw decorative paper, a printing device 20 for printing the stretched out fibre material or paper web 50 with colour and/or at least one pattern or decoration, an impregnating and/or coating device 30, namely an impregnating device 30 arranged in series or in line with the printer device 20.
This impregnating device 30 is designed for impregnating the stretched out fibre material or paper web 50 with aminoplastic and thermally hardening synthetic resin, namely melamine resin. Furthermore, the impregnating device 30 can also be deigned for coating the stretched out fibre material or paper web 50 with a layer comprising a resin, more particularly melamine resin, i.e. with an overlay.
However, in the example of embodiment shown in figure 1, the production installation 100 has a coating unit 40 arranged in series or in line with the impregnating unit 30 for coating the stretched out fibre material or paper web 50 with the overlay.
The printing unit 20 is arranged between the unrolling device 10 and the impregnating unit and is designed for printing the fibre material or paper web 50 by means of the digital printing method.
For the at least partial drying of the printed fibre material or paper web 50, the printing device 20 has a drying device 22. Alternatively (not shown in 1 ,:
figure 1), this drying device 22 can also be arranged in series or in line with the printing device 20 and the impregnating device 30, more particularly between the printing device 20 and the impregnating device 30.
In contrast to the methods known and practised in the state of the art, in which in two separate working stages the decorative paper is first printed, generally using the intaglio method, and then in another installation is impregnated in a second stage, the production installation 100 shown in figure 1 performs an inline process for printing and impregnating and/or coating decorative paper. What is new about this is not the printing itself, nor the impregnating and/or coating, but the fact that this takes place inline during the course of one working process, i.e. on a production installation or machine.
List of references Unrolling device Printing device, more particularly digital printer or intaglio printer 22 Drying device Impregnating and/or coating device Coating device Fibre material or paper web Carrier board, more particularly composite wood board or plastic board 100 Production installation or finishing installation, more particularly a finishing line for producing a coating element, more particularly a decorative layer suitable for coating a carrier board 60 200 Installation, more particularly production line for producing laminate 210 Lamination device
In document DE 600 15 603 T2 it is proposed, in order to avoid match imprecisions of the pattern of a laminate floor, to print this pattern directly onto the carrier board, thus for example directly onto the composite wood board by means of a digital printer. However, the drawback of this is that the surface of the carrier board has to be treated before printing, for example primed and/or ground. Also, in the case of the laminate element in accordance with document DE 600 15 603 T2 only transparent layers can be applied to the carrier board. For example, it is not possible to apply a core or carrier paper layer of kraft pulp to the carrier board.
Explanation of the present invention: objective, solution, advantages On the basis of the aforementioned disadvantages and inadequacies, as well as an evaluation of the described state of the art, the objective of the present invention is to further develop a method of the type set out in the introduction as well as a production installation of the type set out in the introduction so that the coating element can be efficiently manufactured, while reliably avoiding kinks, tears or changes in the shape of the printed fibre material or paper.
This objective is achieved by means of a method with the features set out in clam 1 as well as a production installation with the features set out in claim 5. Advantageous embodiments and expedient further developments of the present invention are characterised in the relevant sub-claims.
The present invention is fundamentally based on designing a series or in-line production installation, such an production line, in which the fibre material or paper is printed in a first stage and then immediately further processed by means of impregnation and/or coating. In accordance with the present invention the supplied fibre material or paper is printed in one production stage and then impregnated and/or coated in the same production stage.
According to the invention, in order to produce at least one coating element, more particularly for producing a decorative coating made of fibre material and resin, more particularly decorative paper and amino-plastic and or thermally hardening synthetic resin for coating at least one carrier board, at least one fibre material or paper web is initially stretched out by unrolling raw fibre material or raw paper, more particularly raw decorative paper. This stretched fibre material or paper web is at least partially printed with colour and/or with at least one pattern or decoration.
The stretched out and printed fibre material or paper web is then at least in parts - impregnated with at least one resin with at least one aminoplastic and/or thermally hardening synthetic resin, for example, melamine resin and/or - coated with a layer containing at least one resin, more particularly at least one aminoplastic and/or thermally hardening synthetic-resin, for example melamine resin, for example with a so-called overlay.
Combining printing and impregnation and/or coating in one production installation or one machine can be achieved by arranging at least one impregnating and/or coating device in series or in ine with at least one printing device. For example, the printing device can be arranged between at least one unrolling device for unrolling the fibre material or paper web, and a first immersion bath, or a first coating device of the impregnating and/or coating device. The unrolling device, printing device and/or coating device are preferably arranged in series, for example on at least one production band or production line, such as on at least one impregnating channel.
In accordance with an advantageous embodiment of the present invention the production installation has the components of a conventional impregnation and/or coating installation. However, these components are arranged so that the stretched out fibre material or paper web can be printed as well as impregnated and/or coated.
The fibre material or paper web can be printed by intaglio printing or by means of digital printing. Using the digital printing method is particularly advantageous as a digital printing device requires little space and can thus be simply integrated into a conventional impregnation machine.
Furthermore, a digital printing device or digital printer does not require cost-intensive printing plates. Other advantages of a digital printing system compared with intaglio printing are the lower investment costs as well as the possibility of simpler and more cost-effective decoration changing. In addition, with a digital printing system raw material storage costs can be reduced as a large number of decorations does not have to be kept in stock.
In accordance with an advantageous embodiment of the present invention the fibre material or paper web is printed by at least one digital printing device. This digital printing device exhibits the properties required for printing the fibre material or paper web and is preferably designed to essentially print the entire width of the fibre material or paper web.
Advantageously the digital printer device is designed to dry the printed fibre material or paper web at least in parts. Drying of the fibre material or paper web can take place by means of air and/or ultra-violet radiation and/or using the method of near infra-red drying. In addition to pure air drying other drying methods, such as UV drying and NIR drying can be used.
Due to its comparatively low printing speed an advantageous embodiment of the printer device has a comparatively short drying section, a few metres in length for example.
After passing through the printing device or printer the known impregnation and/or coating procedure can continue unchanged. For example, the stretched out fibre material or paper web with at least one resin, more particularly at least one aminoplastic and/or thermally hardening synthetic resin, for example melamine resin, can be saturated/impregnated and after saturation or impregnation with - at least one resin, more particularly at least one aminoplastic and/or thermally hardening synthetic resin, for example melamine resin, and/or - fibre material, more particularly cellulose, and/or - provided with a least one layer containing an abrasion-resistant substance, more particularly corundum.
Furthermore, the stretched out fibre material or paper web can, more particularly on its side facing away from the layer with resin, be coated with a core or carrier paper layer, whereby the core or carrier paper layer has at least one fibre material, more particularly paper, for example kraft paper, impregnated with a thermally-hardening synthetic resin, for example phenol resin.
The present invention also relates to a method of producing laminate, for example at least one laminate floor element, at least one laminate work top, a least one wall or ceiling cladding element of a laminate or at least one laminate furniture element, as well an installation relating thereto. In accordance with the invention, to produce laminate at least one coating element is produced by way of a method in accordance with the above type and - then applied to at least one carrier board, more particularly glued and/or stuck and/or pressed to it.
According to an advantageous further embodiment of the method according to the invention for producing a coating element as well as the production installation according to the invention, the stretched out fibre material or paper web of the coating element can also immediately, i.e. in the same production stage, be applied to the carrier board, for example a composite wood board, such as an MDF, HDF, OSB or particle board, or to a plastic board.
In addition, on its side facing away from the coating element, the carrier board can in the same production stage also be coated with at least one backer sheet, for example with at least one veneer and/or with at least one further layer with a thermally-hardening resin. The coating element can be laminated onto the carrier board by means of single-stage or dual-stage process. From the coating element produced in accordance with the invention D[irect]P[ressure]L[aminat], H[igh]P[ressure]L[aminat] as well as C[ontinuous]P[ressure]L[aminat] and also L[ow]P[ressure]L[aminat] can be produced.
The present invention finally relates to the use of a method for producing at least one coating element in accordance with the manner set out above and/or at least one production installation of the above-described type for the line or series production of printed, impregnated and/or coated decorative paper and/or for the line or series production of laminate, more particularly by means of a method for production of a laminate of the above-described type and/or by means of at least one device for producing laminate in accordance with type described above.
Brief description of the drawings As has already been stated, there are various possibilities of advantageously embodying and further developing the teaching of the present invention. With regard to this, reference is made on the one hand to the claims subordinate to claim 1 and to claim 5, and on the other hand further embodiments, feature and advantages of the present invention are explained in more detail below with the aid of the example of embodiment illustrated in figure 1.
Fig. 1 shows a schematic view of a first example of embodiment of a device in accordance with the present invention which operates in accordance with the method of producing or finishing laminate according to the present invention.
Best way of implementing the present invention In the first example of embodiment of the present invention illustrated in figure 1, an installation 200, more particularly a production line, for producing laminate is shown which operates in accordance with the present invention and has several functional components, namely - an example of embodiment of a production installation 100 for producing at least one coating element in accordance with the present invention, whereby the production installation 100 operates in accordance with the method of producing at least one coating element according to the present invention and - a laminating device 210 for applying the coating element, more particularly the stretched out, printed, impregnated and/or coated fibre material or paper web 50 to a carrier board 60.
The production installation 100 is designed for the production of a decorative layer suitable for coating the carrier board 60, whereby the decorative layer comprises at least one printed decorative paper and thermally-hardening synthetic resin.
For this purpose the production installation 100 has an unrolling device 10 designed for stretching out a fibre material or paper web 50 by means of unrolling raw fibre material or raw paper, more particularly raw decorative paper, a printing device 20 for printing the stretched out fibre material or paper web 50 with colour and/or at least one pattern or decoration, an impregnating and/or coating device 30, namely an impregnating device 30 arranged in series or in line with the printer device 20.
This impregnating device 30 is designed for impregnating the stretched out fibre material or paper web 50 with aminoplastic and thermally hardening synthetic resin, namely melamine resin. Furthermore, the impregnating device 30 can also be deigned for coating the stretched out fibre material or paper web 50 with a layer comprising a resin, more particularly melamine resin, i.e. with an overlay.
However, in the example of embodiment shown in figure 1, the production installation 100 has a coating unit 40 arranged in series or in line with the impregnating unit 30 for coating the stretched out fibre material or paper web 50 with the overlay.
The printing unit 20 is arranged between the unrolling device 10 and the impregnating unit and is designed for printing the fibre material or paper web 50 by means of the digital printing method.
For the at least partial drying of the printed fibre material or paper web 50, the printing device 20 has a drying device 22. Alternatively (not shown in 1 ,:
figure 1), this drying device 22 can also be arranged in series or in line with the printing device 20 and the impregnating device 30, more particularly between the printing device 20 and the impregnating device 30.
In contrast to the methods known and practised in the state of the art, in which in two separate working stages the decorative paper is first printed, generally using the intaglio method, and then in another installation is impregnated in a second stage, the production installation 100 shown in figure 1 performs an inline process for printing and impregnating and/or coating decorative paper. What is new about this is not the printing itself, nor the impregnating and/or coating, but the fact that this takes place inline during the course of one working process, i.e. on a production installation or machine.
List of references Unrolling device Printing device, more particularly digital printer or intaglio printer 22 Drying device Impregnating and/or coating device Coating device Fibre material or paper web Carrier board, more particularly composite wood board or plastic board 100 Production installation or finishing installation, more particularly a finishing line for producing a coating element, more particularly a decorative layer suitable for coating a carrier board 60 200 Installation, more particularly production line for producing laminate 210 Lamination device
Claims (10)
1. Method of producing at least one coating element, more particularly a decorative layer suitable for covering at least one carrier board (60), whereby - through unrolling raw fibre material or raw paper, more particularly a raw decorative paper, at least one fibre material or paper web (50) is stretched out and - the stretched out fibre material or paper web (50) is printed at least in parts with colour and/or at least one pattern/decoration, characterised in that after printing, the stretched out fibre material or paper web (50) is, more particularly in an in-line process, at least in parts - impregnated with at last one resin, more particularly at least one animoplastic and/or thermally hardening synthetic resin, for example melamine resin, and/or - coated with at least a layer containing at least one resin, more particularly an aminoplastic and/or thermally hardening synthetic resin, for example melamine resin.
2. Method according to claim 1 characterised in that after printing and before impregnation the stretched out fibre material or paper web (50) is at least partially dried, whereby drying of the fibre material or paper web (50) takes place in particular - by means of air and/or - by means of ultra-violet radiation and/or - by means of the method of near infra-red drying.
3. Method according to claim 1 or 2 characterised in that the printing of the fibre material or paper web (50) takes place by means of - digital printing or - intaglio printing
4. Method of producing laminate, characterised in that, - at least one coating element is produced using a method in accordance with at least one of claims 1 to 3 and - that subsequently the coating element, more particularly the stretched out, printed, impregnated and/or coated fibre material or paper web (50) is applied, more particularly glued and/or stuck and/or pressed, onto at least one carrier board.
5. Production installation (100) for producing at least one coating element, more particularly at least one decorative layer suitable for coating at least one carrier board (60), comprising - an unrolling device (10) for stretching out at least one fibre material or paper web (50) by means of unrolling raw fibre material or raw paper, more particularly raw decorative paper, and - at least one printing device (20) for printing the stretched out fibre material or paper web (50) at least in parts with colour and/or at least one pattern/decoration, characterised in that there is at least one impregnating and/or coating device (30) that is arranged in series with the printing device (20) and is designed - for impregnating, at least in parts, the stretched out fibre material or paper web (50) with at least one resin, more particularly with at least one aminoplastic and/or thermally hardening resin, for example melamine resin, and or - for coating, at least in parts, the stretched out fibre material or paper web (50) with at least one resin, more particularly with at least one aminoplastic and/or thermally hardening synthetic resin, for example melamine resin.
6. Production installation in accordance with claim 5 characterised in that the printing device (20) - is arranged between the unrolling device (10) and the impregnating and/or coating device (30) and/or - is designed to print the fibre material or paper web (50) by means of the method of digital printing or by means of the method of intaglio printing.
7. Production installation in accordance with claim 5 or 6 characterised by at least one drying device (22) - allocated to the printing device (20) or - arranged in series with the printing device (20) and the impregnating and/or coating device (30), more particularly between the printing device (20) and the impregnating device (30), for at least partially drying the fibre material or paper web (50) more particularly by means of - air and/or - ultra-violet radiation and/or - the method of near infra-red drying
8. Production installation according to any one of claims 5 to 7, characterised in that the layer with resin also contains - fibre material, more particularly cellulose and/or - at least one abrasion-resistant or abrasive substance, more particularly corundum.
9. Device (200) for producing laminate, characterised by - at least one production installation (100) according to at least one of claims 5 to 8 and - at least one lamination device (210) designed for applying the coating material, more particularly the stretched out, printed, impregnated and/or coated fibre material or paper web (50) to at least one carrier board (60).
10. Use of a method of producing at least one coating element according to any one of claims 1 to 3, and/or at least one production installation (100) according to any one of claims 5 to 8 - for the inline or series production of printed, impregnated and/or coated decorative paper and/or for the inline or series production of laminate, more particularly by means of a method of producing laminate according to claim 4 and/or at least one device (200) for producing laminate according to claim 9.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA2678557A CA2678557A1 (en) | 2009-09-14 | 2009-09-14 | Method of manufacturing coating elements and production installation relating thereto |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA2678557A CA2678557A1 (en) | 2009-09-14 | 2009-09-14 | Method of manufacturing coating elements and production installation relating thereto |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2678557A1 true CA2678557A1 (en) | 2011-03-14 |
Family
ID=43759547
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA2678557A Abandoned CA2678557A1 (en) | 2009-09-14 | 2009-09-14 | Method of manufacturing coating elements and production installation relating thereto |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2678557A1 (en) |
-
2009
- 2009-09-14 CA CA2678557A patent/CA2678557A1/en not_active Abandoned
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| Date | Code | Title | Description |
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| EEER | Examination request | ||
| FZDE | Dead |
Effective date: 20150915 |