CN102741049A - 明亮颜色的表面层 - Google Patents

明亮颜色的表面层 Download PDF

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CN102741049A
CN102741049A CN2010800608816A CN201080060881A CN102741049A CN 102741049 A CN102741049 A CN 102741049A CN 2010800608816 A CN2010800608816 A CN 2010800608816A CN 201080060881 A CN201080060881 A CN 201080060881A CN 102741049 A CN102741049 A CN 102741049A
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G·齐格勒
K·林德格伦
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Valinge Innovation AB
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Abstract

本发明涉及通过使用干粉末层来生产淡色和/或素色耐磨表面层的方法，所述干粉末层包括精炼纤维、粘合剂、颜料和耐磨颗粒的混合物。

Description

明亮颜色的表面层
技术领域
本发明一般地涉及具有耐磨表面层的纤维基镶板的领域，其用于建筑镶板，优选地板镶板。本发明涉及具有这样的耐磨表面的建筑镶板，以及生产这种镶板的生产方法。
背景技术
应用领域
本发明尤其适合于用在浮动地板中，所述浮动地板由包含木纤维芯部和装饰性耐磨表面的地板镶板形成。因此，以下对于已知系统的技术和问题以及本发明的目的和特征的描述将作为非限制性示例首先针对此应用领域，尤其是针对类似于传统的浮动的木纤维基层压地板的地板。本发明不排除向下粘接到底层地板的地板。
应强调的是，本发明的实施例可用作镶板或表面层，所述表面层例如粘接到芯部上。本发明的实施例也可以用在诸如墙壁镶板、天花板以及家具部件等的应用中。实施例也可以用在具有任选的表面材料例如软木或木材的地板中，以便提高耐磨和设计特性。
背景
生产具有包含层压纸片的表面的层压建筑镶板是公知的。
在WO 2009/065769中公开了一种称为“木纤维地板（WFF）”的新类型的镶板，该文献公开了产品和生产这种产品的方法。直接压制的层压建筑镶板通常包括由6-12mm的纤维板构成的芯部，由层压板构成的0.2mm厚的上部装饰表面层，以及由层压板、塑料、纸或类似材料构成的0.1-0.2mm厚的下部平衡层。
层压表面通常包括两个纸片，即，0.1mm厚的印制的装饰纸和透明的0.05-0.1mm厚的覆盖纸，所述覆盖纸施加在装饰纸上方并旨在保护装饰纸免于磨蚀。在装饰性的非透明纸上的印记仅为大约0.01mm厚。由精制的α-纤维素纤维制成的透明的覆盖纸包含小而硬且透明的氧化铝颗粒。所述精制的纤维相当长，大约2-5mm，这使得覆盖纸具有需要的强度。为了获得透明性，已经移除了存在于天然木纤维中的所有天然树脂，并且将氧化铝颗粒作为非常薄的层施加在装饰纸之上。层压地板的表面层的特征在于，通常通过一个在另一个之上的两个单独的层获得装饰和耐磨性能。
印制的装饰纸和覆盖纸用三聚氰胺树脂浸渍，并且在热和压力下层压到基于木纤维的芯部上。
小的氧化铝颗粒可具有在20-100微米范围内的尺寸。所述颗粒可通过多种方式结合在表面层中。例如，它们可以在覆盖纸的制造期间结合在纸浆中。它们也可以在覆盖纸的浸渍操作期间喷洒在湿的涂料上，或者结合在用于浸渍覆盖纸的涂料中。
也可以不通过纤维素覆盖层来生成耐磨层。在这种情况下，以和上述类似的方法将三聚氰胺树脂和氧化铝颗粒作为涂料层直接施加在装饰纸上。这种耐磨层通常被称为液体覆盖层。
通过这种生产方法可以获得非常耐磨的表面，这种表面主要用在层压地板中，但是也可以用在家具部件和类似应用中。高品质层压地板的耐磨性为4000-6000转，这对应于根据ISO标准通过泰伯磨耗试验机（TaberAbraser）测得的磨耗等级AC4和AC5。
还已知可以通过将氧化铝颗粒结合在覆盖木质表面的透明涂料中来显著提高涂漆的木质表面的耐磨性。
用在层压地板中的最常用的芯部材料是具有高密度和良好稳定性的通常称为HDF（高密度纤维板）的纤维板。有时也使用MDF（中密度纤维板）作为芯部。还可以使用其它芯部材料例如刨花板。
WFF地板镶板是“无纸”的，其中表面层包含木纤维、粘合剂和耐磨颗粒的基本同质的混合物。耐磨颗粒优选为氧化铝颗粒，粘合剂优选为热固性树脂例如三聚氰胺。从顶部到底部贯穿表面层的厚度提供耐磨颗粒，并且与镶板的芯部接触。其它合适的材料例如为硅石或碳化硅。一般来说，所有这些材料优选以干的形式作为混合粉末施加在HDF芯部上，并且在热和压力下固化为0.2-1.0mm的表面层。
一些术语的定义
在下文中，安装好的地板镶板的可见表面称为“正面”，而地板镶板的面对底层地板的相对侧称为“背面”。包含镶板的主要部分并且为镶板提供需要的稳定性的片状材料称为“芯部”。当芯部在最靠近正面处覆盖有表面层并且在最靠近背面处优选还覆盖有平衡层时，它形成半成品，在所述半成品在随后的操作中被分成多个地板元件的情况下，其被称为“地板块”或者“地板元件”。当地板元件沿它们的边缘被加工以获得具有接合系统的最终形状时，它们被称为“地板镶板”。“表面层”是指赋予镶板装饰特性和耐磨性的所有层，其在最靠近正面处施加到芯部上并优选地覆盖地板块的整个正面。“装饰表面层”是指主要旨在赋予地板装饰性外观的层。“耐磨层”是指主要适于提高正面的耐久性的层。
“水平面”是指平行于表面层的外部部分延伸的平面。“水平地”是指平行于水平面，“竖直地”是指垂直于水平面。“向上”是指朝向正面，“向下”是指朝向背面。
发明内容
本发明的实施例的总的目的是提供一种建筑镶板，优选为一种具有淡色和/或素色（例如亮白）的耐磨层的地板镶板，其能够以比当前已知的技术更加成本高效的方式生产。
WO 2009/065769中所描述的方法包括使用天然的或回收的木纤维，其局限性是，当使用旨在赋予淡色（例如亮白色）或非常热烈的颜色的颜料时，由于纤维的天然树脂，所述天然的或回收的木纤维的天然颜色会得到不是很淡的或者不是很艳丽的结果。天然树脂使得难以获得希望的颜色，并且可能导致褪色的区域。可以通过增加颜料的量来解决色彩度受限的问题，但是这是一个相当昂贵的解决方案，并且高的颜料负载可能导致其它问题，例如颜料流出。
传统的层压地板镶板在制造淡色的或者艳丽色彩的表面时具有局限性，这是由于高度耐磨覆盖层的有限的透明度。
该问题的一个解决方案是使用包含精炼纤维、粘合剂、颜料和耐磨颗粒的混合物的干粉末层。
本发明的一个方面是一种生产淡色的耐磨表面层的生产方法，包括以下步骤：
·在载体上施加干粉末层，所述干粉末层包括精炼纤维、粘合剂、颜料和耐磨颗粒的混合物；以及
·通过在所述混合物上施加热和压力，将所述混合物固化为艳丽的或亮白的耐磨层。
所述粘合剂优选为三聚氰胺树脂，所述耐磨颗粒优选为氧化铝。用于制造亮白产品的颜料优选为二氧化钛、氧化铅或其它常用的颜料。用于制造非常艳丽的产品的颜料包括无机和有机成因（origin）的各种各样的颜料。
所述混合物施加于其上的载体优选为HDF镶板，所得到的镶板因而具有从顶部到底部贯穿表面层的厚度的耐磨颗粒，并且所述耐磨颗粒与镶板的芯部接触。
所述精炼纤维是明显不含有通常在木纤维或其它天然纤维中发现的天然树脂的纤维。可以通过洗涤、提取、漂白或其组合来获得这种纤维。这种纤维的一个示例是
Figure BDA00001859675800041
150TAB，其可以由CFF公司（德国）提供。
在一个优选实施例中，在干粉末层中与精炼纤维（例如白色纤维）的量相比的树脂的量高于大约100%，优选高于大约120%，最优选在大约120%至180%的范围内。这种比例具有的效果是，提高了可加工性并且提高了耐污染性。
底层（散布在芯部上的层）与在底层上方的干粉末层的组合使得能够获得甚至更好的可加工性，例如印花深度和更高的光泽。在实施例中，所述底层包括木纤维和树脂，所述木纤维优选为天然木纤维或HDF纤维，但是可以使用精炼纤维。在一个优选实施例中，与木纤维的量相比的树脂的量小于大约100%，优选低于大约200%，更优选低于大约300%，甚至可以低于大约400%。
放置在干粉末层上方的由精炼纤维组成的顶层（不具有任何氧化铝）进一步提高了耐污染性。它还增加了压板的寿命。
本发明的实施例包含多个层的以下组合：（1）底层和干粉末层；（2）干粉末层和顶层；以及（3）底层、干粉末层和顶层。
还可以使用精炼纤维和HDF纤维或任何天然木纤维（即，未精炼的木纤维）的混合物，以便降低成本和/或生成其它颜色。
配料的许多组合可以制成完全功能性的产品。给出两个示例以示出本发明创造的两个功能性范例。
附图说明
下面将参照所附的示例性图结合优选实施例对本发明进行更详细描述，其中：
图1示出根据本发明的一个实施例的地板镶板。
具体实施方式
提供镶板1，该镶板1具有木纤维基芯部6、均质非透明装饰表面层5以及优选地平衡层。在一个实施例中，镶板1在生产过程中一体地形成，其中所述表面层、芯部和平衡层在相同的压制操作中形成。
图1示出表面层5。它包括精炼纤维14、小而硬的耐磨颗粒12、12’以及粘合剂19的混合物。耐磨颗粒12、12’优选为氧化铝颗粒。
所述表面层还包括颜料15和/或任选的其它装饰性材料或化学物质。装饰性材料例如包括可以影响表面层的设计方面的材料。示例性的设计材料包括影响纹理、反射率、光泽度、发光性、透明性等的材料。
本发明的实施例提供的优点是，耐磨表面层5能够制成为比已知的层压地板镶板中更厚得多。
优选的粘合剂是三聚氰胺或尿醛树脂。可以使用任何其它粘合剂，优选合成热固性树脂。
在根据本发明的实施例的方法中，优选使用与WO 2009/065769中所公开的相同的散布和压制单元，并且在该方法中优选地连同经构造的压板一起使用。
示例W1：亮白配方
在厚度为9.8mm的HDF板上，两个背纸NKR140固定在背面用于平衡，添加WFF粉末配方，其包含40Wt%（即，按重量计的百分比）的精炼纤维，10Wt%的氧化铝，作为颜料的10Wt%的二氧化钛，以及40Wt%的三聚氰胺树脂。通过所谓的散布机器（scattering machine）施加WFF粉末混合物，所述散布机器将WFF粉末材料均匀地分布在HDF表面上。WFF粉末的总量是625g/m2。通过在WFF粉末上喷洒水溶液将WFF粉末固定在HDF板上，所述水溶液包含97Wt%的去离子水，1Wt%的BYK-345（为减小表面张力而添加的润湿剂）和2Wt%的Pat 622/E（脱离剂）。
将上述材料放置到所谓的DPL压机中。表面纹理由具有峰和谷的特殊压板构成，所述峰和谷的最高和最低部分的差大约为300微米。当压制DPL和HPL时，不能使用这种深的压板，三聚氰胺浸渍的纸在压制期间会破裂。所得到的产品是亮白的建筑镶板。
粉末混合物的其它示例在下面列出。
  类型   W1   W2   W3   W4   底层   W5
  HDF纤维Wt%   0   0   0   0   75   0
  白色纤维Wt%   40   40   35   30   0   39
  Prefere 4865Wt%   0   40   45   52   25   0
  Kauramine 773Wt%   40   0   0   0   0   50
  TiO2Wt%  10   10   10   9   0   11
  Al2O3Wt%  10   10   10   9   0   0
  总共Wt%  100   100   100   100   100   100
在以上混合物中，使用了Prefere 4865和Kauramine 773，它们是三聚氰胺甲醛树脂的示例。
对于W3和W4，树脂与白色纤维（精炼纤维）相比的比率是增加的。增加的比率的效果是，可加工性增加并且耐污染性提高。在一个优选实施例中，树脂与白色纤维相比的比率高于大约100%，优选高于大约120%，最优选在大约120%至180%的范围内。
底层（散布在芯部上的层）与在底层上方的所述层W1-W4中的任何一个的结合使得能够获得甚至更好的可加工性，例如印花深度和更高的光泽。
在所述层W1-W4中的任何一个上方的不具有任何氧化铝的顶层例如W5进一步提高了耐污染性。它还增加了压板的寿命。
示例R2：艳丽红色配方
在厚度为9.8mm的HDF板上，两个背纸NKR140固定在背面用于平衡，添加WFF粉末配方，其包含42.5Wt%的精炼纤维，10Wt%的氧化铝，作为红色颜料的5Wt%的Heucosin Spez.Tomatenrot G 10138，以及42.5Wt%的三聚氰胺树脂。通过所谓的散布机器来施加WFF粉末混合物，所述散布机器将WFF粉末材料均匀地分布在HDF表面上。WFF粉末的总量是625g/m2。通过在WFF粉末上喷洒水溶液将WFF粉末固定在HDF板上，所述水溶液包含97Wt%的去离子水，1Wt%的BYK-345（为减小表面张力而添加的润湿剂）和2Wt%的Pat 622/E（脱离剂）。
将上述材料放置到所谓的DPL压机中。表面纹理由具有峰和谷的特殊压板构成，所述峰和谷的最高和最低部分的差大约为300微米。当压制DPL和HPL时，不能使用这种深的压板，三聚氰胺浸渍的纸在压制期间会破裂。所得到的产品是艳丽的纯红色建筑镶板，其在不使用精炼纤维的情况下不易获得。
喷洒在WFF粉末上的水溶液例如可以包含80-100Wt%的水，优选为去离子水，0-10Wt%的润湿剂和0-10Wt%的脱离剂。更优选地，所述水溶液例如可以包含95-98.5Wt%的水，优选为大约97Wt%，0.5-2Wt%的润湿剂，优选为大约1Wt%，以及1-3Wt%的脱离剂，优选为大约2Wt%。

Claims (16)

1.一种制造耐磨表面层的方法，包括以下步骤：
·在载体上施加干粉末层，所述干粉末层包括精炼纤维、粘合剂、颜料和耐磨颗粒的混合物；以及
·通过在所述混合物上施加热和压力，将所述混合物固化为淡色的耐磨层。
2.根据权利要求1或2所述的方法，其特征在于，将装饰层连接到基于木纤维的芯部以获得镶板。
3.根据以上权利要求中任一项所述的方法，其特征在于，所述镶板是地板镶板。
4.根据以上权利要求中任一项所述的方法，其特征在于，所述耐磨颗粒是氧化铝。
5.根据以上权利要求中任一项所述的方法，其特征在于，固化的层的厚度小于大约1mm。
6.根据以上权利要求中任一项所述的方法，其特征在于，所述淡色耐磨表面层是亮白或红色的。
7.根据以上权利要求中任一项所述的方法，其特征在于，将装饰层连接到HDF镶板。
8.根据以上权利要求中任一项所述的方法，其特征在于，固化的层的厚度小于大约0.3mm。
9.根据以上权利要求中任一项所述的方法，其特征在于，树脂与精炼纤维相比的比率高于大约100%。
10.根据以上权利要求中任一项所述的方法，其特征在于，树脂与精炼纤维相比的比率高于大约120%。
11.根据以上权利要求中任一项所述的方法，其特征在于，树脂与精炼纤维相比的比率在大约120%至大约180%的范围内。
12.根据以上权利要求中任一项所述的方法，其特征在于，所述方法包括在芯部上散布底层的步骤。
13.根据以上权利要求中任一项所述的方法，其特征在于，所述方法包括在干粉末层上方散布顶层的步骤。
14.根据权利要求1所述的方法，其特征在于，所述表面层是淡色和/或素色的。
15.根据以上权利要求中任一项所述的方法生产的地板镶板。
16.根据权利要求15所述的地板镶板，其特征在于，所述地板镶板的表面层是淡色和/或素色的。
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