CN104245805B - 一种生产装饰薄板的方法及其应用 - Google Patents

一种生产装饰薄板的方法及其应用 Download PDF

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CN104245805B
CN104245805B CN201380020396.XA CN201380020396A CN104245805B CN 104245805 B CN104245805 B CN 104245805B CN 201380020396 A CN201380020396 A CN 201380020396A CN 104245805 B CN104245805 B CN 104245805B
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woven
printing
coating
fancy veneer
radiation
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CN104245805A (zh
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E·霍夫
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Surface Technologies GmbH and Co KG
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Abstract

用于生产装饰层压板的基于纤维素非织物(如纸)的装饰薄板在合成树脂中浸渍。因此，它们的尺寸发生变化，变得易碎并且在层压板中不能防水。在根据本发明的方法中，已印刷或未印刷的非织物由紫外线照射交联聚合物的水分散体浸渍，干化并可选地印刷，并且最终经紫外线照射。由此方式获得的装饰薄板在层压板中可防水，并且在每个工艺步骤之后均可盘绕存储。

Description

一种生产装饰薄板的方法及其应用
技术领域
本发明涉及一种生产装饰薄板的方法，此装饰薄板用于生产具有其它层的装饰层压板，例如还具有由木材、木基材料以及塑料构成的载体层以及覆盖或保护层。所述装饰层压板例如可用作墙壁或地板覆盖物，还可用于家具结构中。本发明还涉及该装饰薄板在装饰层压板制造过程中的应用。
背景技术
在这样的层压板中，装饰物可以模拟其它材料，例如木头、陶瓷、自然或人工石，或者在艺术或者实用方面进行考虑。通常，装饰物多少需要一些透明的硬质塑料层以防止磨损。通常还在覆盖层表面提供与装饰物具有空间关系的结构，模拟所要模仿的材料的表面结构，称为同步纹。
装饰物通常是以印刷纸或者具有图案的纸或其他纤维素非织物的方式实现，其浸有固化清漆或者合成树脂，位于载体和抗磨损外覆盖层之间。通常，生产浸渍装饰纸需要独立的印刷和浸渍生产过程，这通常需要在实际的层压生产过程以外的工厂中实现，带来了很大的成本因素。装饰纸的浸渍材料与覆盖层的清漆或者人工树脂之间的兼容性也是必要的，该浸渍材料尤其不能接触清漆和合成树脂。
此技术的另一个问题在于装饰纸浸渍时，纸张的尺寸会变化，因此在后续的工艺中需要考虑装饰物与表面结构(同步纹)之间的空间关系必须得到保持。当产品频繁更换时，这是尤其困难的。
聚酰胺塑料浸渍的装饰纸还对水敏感，水可从切割边缘绕过覆盖层渗入层压板内。为了在潮湿区域中应用，这样的层压板件一定要密封，特别是要防止水在侧边渗透进入。
最后，装饰纸通常会由于浸渍而失去柔韧性，不能够再盘绕，而是需要将其切割成载体大小的薄板以进行处理。
DE1704598A描述了一种连续生产纤维增强塑料薄板的方法，其中非织物浸渍有含自交联组的合成树脂，并随后受加热和压缩处理。
DE10134302C1披露了一种用于生产装饰层压板的预浸材料的生产方法，其中热固化树脂应用于非涂覆纸上，并且将预浸材料的剩余湿度调节到约3％，其中树脂依然保持非交联。
WO2010/089086A1描述了一种生产装饰纸的方法，其中对纸张进行印刷，并且随后在其上应用脂族、含聚碳酸酯的阴离子聚氨酯分散体(dispersion)。之后，对纸张进行氨基塑料树脂浸渍。这会节约浸渍树脂，使纸张在浸渍氨基塑料树脂时减少生长，并且提高了装饰纸的耐光性。
发明内容
本发明的目的在于提供一种生产纤维素非织物装饰薄板的方法，其带来一个完整并防水的纤维素浸渍，与现有技术相比其实现方式更简单。
此目的是通过主权利要求的方法实现的。
经发现，当使用紫外线(UV)辐射交联聚合物的水分散体作为浸渍剂，通过紫外线辐射交联干化浸渍的聚合物并对其进行固化处理，就可以以简单的方式获得一装饰薄板，该装饰薄板相对于原来的纤维素非织物在尺寸上无变化，能与用于其他层的树脂共存，特别是与氨基塑料共存，这些其它层包括装饰层压板树脂的覆盖层，可提供良好的结合并且完全防水。
优选地，本发明使用的由纤维素纤维构成的非织物除可选地具有少量用于固定非织物的粘合剂外，不含有其他的浸渍剂。单位区域的重量通常在50-200g/m2之间。更优选地，该非织物为纸。单位区域的重量优选范围在70-100g/m2之间。可以适当应用装饰表面领域中已知的印刷原纸。这些纸一般没有被浸渍，可被染色并且含有颜料成分，以使其可遮挡未处理载体材料的颜色和结构。
根据本发明的方法，由纤维素纤维制成的非织物可以在印刷或未印刷状态下浸渍。在第一种情况下，交联聚合物在浸渍和干化之后通过紫外线辐射交联并固化。在第二种情况下，在被照射之前，装饰必须要印刷在已浸渍并干化的非织物上。第二个实施例的一个优势在于，装饰物的印刷要比非浸渍非织物的印刷少用高达50％的油墨。这要归因于所有的油墨都存留在浸渍非织物的表面，而没有吸收到非织物的内部，而油墨在内部是不可见的。在已浸渍并干化，但尚未被照射的非织物上印刷的另一个优势在于印刷图像变得更加清晰和锐利。明显地，与在原纸上印刷相比，在这里油墨更不容易弥散。
本发明方法中使用的由紫外线辐射交联的聚合物是以水分散体形式存在的，其可选地含有合适的表面活性剂。该聚合物可以是包括交联共聚物单体的共聚物，例如丙烯酸酯和甲基丙烯酸酯之类的烯属不饱和化合物，其甚至在聚合之后，还具有烯属不饱和基团，如多羟基醇的丙烯酸酯类。
优选地，交联聚合物除烯属不饱和共聚物单体外，还包括聚安酯单元，其以一种已知的方式由二异氰酸盐和二醇组成。阴离子分散体是尤其合适的。
另一优选方案为，聚合物除具有交连共聚物单体和氨基甲酸乙酯单元外，还包括酯单元。该聚合物可以表现为嵌段共聚物。例如，聚酯嵌段可以利用二醇，优选为脂肪族聚酯二醇，吸收到共聚物中。
优选地，本发明使用的由紫外线辐射交联的聚合物的水分散体在重量上至少具有35％的固体成分。该分散体可包括其它辅助剂，如去沫剂和增稠剂。优选地，聚合物分散体的面涂覆满足10-40的干面密度，更优选地，得到10-20g/m2的聚合物。通常，纤维素非织物的更高的(每平方米)克重和更大的孔隙体积需要更高的聚合物面密度。
可采用已知的方法实现非织物的浸渍，如将非织物浸入聚合物分散体内。然而，份量法是优选的，可以精确控制面密度，例如辊筒涂色或幕涂色。在辊筒涂色中，浸渍剂优选地通过反压辊压入非织物。还可以采用刮片技术，如纸机涂布机。优选地，辊筒涂色工艺采用由不锈钢或硬橡胶制成的辊筒。
对于浸渍，聚合物分散体可以通过使用合适的增稠剂增加粘稠度，例如基于聚氨酯的组合物。
非织物浸渍之后，通过干化去除水分散介质。干化可以通过物理方法实现，例如红外照射、热空气，例如循环空气或者喷嘴式干燥机、微波、加热辊，或者这些处理的组合。由于浸渍非织物的防水性提高了，因此超出分散体聚合物的成膜温度是有益的。除了水本身，可选地，极性辅助分散剂，如酒精，均属于在干化过程中去除的水分散介质。
本发明方法的一个特别的优势在于浸渍纤维素非织物在干化状态下具有柔韧性而且不发黏，因此它可以毫无问题地盘绕，并可以储存运输以供将来使用。如果必要，本发明方法中的纤维素非织物可以在任何阶段中切割。例如为了使其适应浸渍或印刷装置的宽度，或者适应用于生产装饰层压板的载体板的尺寸。
如果在浸渍过程之前尚未印刷非织物，本发明可在浸渍过程之后，紫外线辐射交联之前完成印刷。已经发现，印刷油墨的黏附在照射之后不符合要求。作为印刷方法，一般的胶版印刷、柔性版印刷，以及数字方法，如喷墨印刷、转移印花或激光印刷都在考虑范围之内。
在这里，数字印刷工艺是特别优选地，因为其不需要与预制印刷体一起工作，而预制印刷体的图案通常是自我重复的。由于这些重复，自然材料，如木材的模拟将变得不完美。在每次印刷之后需要改变印刷体，以避免重复的印记，这是没有效率的。然而利用数字印刷，可以存储大量以数字形式存在的不同图案，不必在安装时间之间改变，即不需要花费时间改变印刷体。在生产过程中，如果被模拟的材料改变，例如需要选择另一种木质材料时，同样具有成本益处。
数字印刷工艺的另一个优势在于它们通常以非接触方式操作。这避免了已经浸渍并干化，但尚未被紫外线辐射的纤维素非织物表面遭到破坏。至于印刷工艺，例如带有固定或移动印刷头的喷射印刷、如具有黑白或彩色复印粉的激光印刷工艺，以及热转移印花工艺都在考虑范围之内。照射固化油墨是有益的，由于在对浸渍评估必要的紫外线照射中，会使油墨与非织物的浸渍剂牢固胶接。然而，其它油墨，如水基或者溶剂型油墨也适用于本发明。
为了形成特殊的视觉效果，还可能采用两个处理步骤印刷装饰，即浸渍过程之前和之后。如果使用如金属反射或乳色油墨，这会是有益的。
本发明还包括一种在生产装饰层压板的方法中对本发明装饰薄板的使用。该方法至少包括下述步骤：
-将装饰薄板附加至载体板；并且
-将覆盖层附加至装饰薄板。
可以考虑采用任何合适的材料作为载体板，如木材、木基材料，如硬纸板及纤维板、夹板、热固性和热塑性材料薄板、生物纤维材料薄板，如麻纤维、纤维素纤维(纸、纸板及其他)或稻菜、陶瓷材料，如耐火粘土、石膏以及所述材料中的两个或多个的混合物，如石膏板或纤维增强塑料，等等。如果载体板在其表面上具有比较顽固的缺陷，就需要应用底漆层，在贴合饰薄板之前弥补这些缺陷。
为了使装饰薄板连接到载体板，优选地，要使用粘合剂或者胶合物。例如包括热溶粘合剂、分散粘合剂、双组分粘合剂、脲醛胶等，可选地，包括硬化剂。必要地或者有益地，可以通过加压以及/或者加热加强粘合剂或者胶合物的效果。
用于保护装饰物的覆盖层施加在连接到载体板的装饰薄板上。为了达到此目的，相关领域内所有的材料和工艺都是适用的。例如，可以采用所谓的覆盖物，该覆盖物通常由浸渍有如聚酰胺塑料的合成树脂的纤维素非织物构成。另一方面，也可能采用无纤维素的覆盖层，例如，采用干化聚酰胺塑料或聚酰胺塑料前体的水溶液，并将其应用到装饰层上。还可在装饰薄板上散布合成树脂或树脂前体的粉末，并通过至少部分熔解形成连续层。该覆盖层还可以由辐射固化清漆形成。在这种情况下，覆盖层的最终硬度可通过照射获得。可以在覆盖层添加减少磨损的成分，例如，金刚砂颗粒、碳化硅、玻璃及其类似物。
优选地，覆盖层由氨基塑料树脂或其前体构成，例如氨基的低聚物以及醛化合物，例如三聚氰胺及蚁醛。为了获得最终的硬度，还需要对材料进行热处理，优选地在压力环境下执行。为了达到该目的，优选地，对整个层组合，包括载体板、装饰薄板及装饰层，进行压缩和/或加热。这可以通过譬如所谓的短周期压力机，或者甚至连续的双压带机实现。在加压之前或者期间，例如用于模拟木材孔隙的表面结构例如可通过合适的凹凸版，压印覆盖层的表面。本发明方法的优势在于，在浸渍之前印刷装饰物，装饰薄板不会由于浸渍和干化工艺而发生尺寸变化，从而印刷装饰保持其表面结构的局部一致。
本发明方法的示例性实施例会在下文中描述。
单位面积重量为80g/m2的纸幅由一对辊筒引导，其中两个辊筒均通过一刮刀装置涂覆20g/m2的氨酯-丙烯酸油酯共聚物分散体，其中所述共聚物具有50wt.-％的固体成分。与纸接触后分散体被压入纸内。在涂覆工艺之后，纸幅通过烘干机，在其中对纸幅进行红外照射，并且开孔。在通过烘干机之后，纸幅在通过印刷台，在其中在纸幅的一侧通过数字喷墨印刷工艺印刷四色装饰。因此，该纸幅从两侧接受紫外线照射。然后，以此方式制作的装饰薄板具有防水性，并且可盘绕和存储。或者，其可立即，可选地在连续操作中，通过脲醛胶胶合在HDF板上。即使在这种状态下，中间产品，即附有装饰薄板的载体板可以可选地存储，以供将来使用。为了完成装饰层压板，现将三聚氰胺甲醛树脂先体的水溶液应用于装饰表面，干化并在约170℃的温度下短周期地加压20秒钟。因此，通过凹凸板，将与孔隙结构匹配的装饰压印入表面。
如果浸渍使用预印装饰纸，则印刷工艺可以省略，而其余的工艺步骤可以同样的方式执行。
附图说明
以下结合附图对本发明另外两个示例性实施例进行更详细地描述。在附图中：
图1描述了本发明中具有非印刷纤维素非织物的方法的第一实施例；以及
图2描述了根据本发明的采用预印刷装饰纸的方法的第二实施例。
具体实施方式
图1所示为本发明方法的第一示例性实施例的连续步骤。在这里，下划线标注的术语表示优选程序，这些程序使本发明尤其具有有益的实用性。首先根据本发明，纤维素非织物在浸渍剂中浸渍，其例如可为未印刷纸张，特别地，为印刷原纸。之后，对浸渍的纤维素非织物进行干化。在这种状态下，非织物可以盘绕并存储，或者已经被印刷。然而优选地，它黏附在载体板上，并且优选地通过数字印刷工艺印刷装饰图案。该步骤之后为紫外线照射工艺，直到浸渍物被充分固化。现在，覆盖层，如覆盖物(浸渍有覆盖层材料的背层)、树脂先体的溶液或者可选的照射-固化漆可以应用于装饰图案上。最后，覆盖层在加压以及/或者加热环境下热压胶接在载体板和装饰层上，其中可选地，采用结构压板将表面结构压印入覆盖层的表面。在一个优选工艺中，一个工艺步骤之后可立即执行另一工艺步骤，以使操作过程连续，这对于大批量生产具有非常大的成本优势。另一方面，已浸渍和干化的纤维素非织物可以盘绕起来，并且在印刷、经紫外线照射、胶接到载体板之前得到立即存储，可选地应用覆盖层，并且对层状的复合结构进行压合和压印。在这里，甚至在印刷处理和紫外线照射之后，材料还可以盘绕起来存储，这是非常有益的。这有利于，譬如经常更换产品的小批量生产。还可能在将装饰层胶接至载体层之后中断生产过程，并存储此中间产品。
图2所示为根据本发明方法的第二示例性实施例。这里，从已经印刷的装饰纸开始。根据本发明首先对合成物进行浸渍，干化和紫外线照射。优选地(标注下划线的工艺步骤)，将其盘绕起来以立即存储，供将来使用。然而，还可以立即或者在中间存储后将其胶接到载体板和覆盖层，如上所述。这些层依次经过加压和/或加热处理，其中可选地，一结构被压印入其表面。

Claims (10)

1.一种生产装饰薄板的方法，包括以下步骤：
-提供未印刷的纤维素纤维非织物；
-利用一受UV辐射交联的聚合物的水分散体浸渍非织物；
-通过干化从浸渍非织物中移除水分散体介质；
-在干化的浸渍非织物的一侧上印刷装饰；以及
-通过使用UV辐射的交联固化非织物中的聚合物，其中纤维素纤维非织物在装饰物的印刷之前连接到载体板。
2.根据权利要求1所述的方法，其特征在于，所述受UV辐射交联的聚合物为一至少包括氨基甲酸乙酯以及烯属不饱和单元的共聚物。
3.根据权利要求2所述的方法，其特征在于，所述受UV辐射交联的聚合物还包括酯单元。
4.根据上述权利要求任一所述的方法，其特征在于，采用未印刷的纸张作为非织物。
5.根据权利要求1所述的方法，其特征在于，所述水分散体具有至少35wt.％的固体成分。
6.根据权利要求1所述的方法，其特征在于，干化处理通过红外辐射、热空气、微波以及/或者热辊筒实现。
7.根据权利要求1所述的方法，其特征在于，印刷处理通过胶版印刷、柔性版印刷以及/或者数字印刷工艺实现。
8.根据权利要求7所述的方法，其特征在于，印刷处理通过喷墨、转移印花或激光印刷工艺实现。
9.在生产装饰层压板的方法中对根据权利要求1-8中任一项生产的装饰薄板的应用，包括以下步骤：
-将覆盖层应用到所述装饰薄板上。
10.根据权利要求9所述的应用，其特征在于，应用覆盖层后，对层组进行加压和/或加热，以及/或者对覆盖层的表面进行凸压花处理。
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UA110890C2 (uk) 2016-02-25
KR20150008862A (ko) 2015-01-23
EP2847258A1 (de) 2015-03-18
MX2014012785A (es) 2014-11-21
PL2847258T3 (pl) 2017-06-30
EP3059276B1 (de) 2017-12-20
CA2866855C (en) 2016-10-11
BR112014026478A2 (pt) 2017-06-27
WO2013167533A1 (de) 2013-11-14
MX348990B (es) 2017-07-06
RU2588624C1 (ru) 2016-07-10
PL3059276T3 (pl) 2018-06-29
PT3059276T (pt) 2018-03-05
EP2847258B1 (de) 2016-11-23
BR112014026478B1 (pt) 2020-12-15
CN104245805A (zh) 2014-12-24
CL2014002930A1 (es) 2015-01-16
DE102012207845A1 (de) 2013-11-14
US10815621B2 (en) 2020-10-27
PT2847258T (pt) 2017-02-03
EP3059276A1 (de) 2016-08-24
CA2866855A1 (en) 2013-11-14
CN106182987A (zh) 2016-12-07
AU2013258170A1 (en) 2014-11-27
ES2613843T3 (es) 2017-05-26
AU2013258170B2 (en) 2015-09-03
JP2015521119A (ja) 2015-07-27
TR201802496T4 (tr) 2018-03-21
CN106182987B (zh) 2019-03-15
JP6089097B2 (ja) 2017-03-01
US20150068671A1 (en) 2015-03-12
KR101953426B1 (ko) 2019-02-28

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