CN106460345A - 用于层压体制造的方法 - Google Patents
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Abstract
本发明涉及一种用于制造具有纤维素层(4)的浸渍物的方法,所述纤维素层由三聚氰胺树脂浸渍以用于构成芯浸渍结构,其特征在于,在所述被芯浸渍的纤维素层(4)的上侧(O)和/或下侧(U)上施加由具有异氰酸酯基成分的液态介质组成的垫层(2)。
Description
技术领域
本发明涉及一种用于制造具有纤维素层的浸渍物的方法,所述纤维素层由三聚氰胺树脂进行浸渍,用于构成芯浸渍结构。
背景技术
浸渍物尤其是作为半成品(Vorprodukte)在制造层压体时得以使用。层压体(Laminate)譬如在木材行业被用于木材板的涂层(Beschichtung)。为了芯浸渍结构,纤维素层由可热固化的三聚氰胺树脂进行浸润,从而浸渍物能够与木材板或者其它浸渍物(尤其是专用纸或者硬纸)压紧。也就是说,已完成的浸渍物首先是如下半成品:该半成品以一个或多个层被直接压到待涂层的木材板、譬如碎料板或者中密度或高密度的纤维板(MDF,HDF)上。在压紧之后,得到可承受高的化学、热以及机械负载的涂层。浸渍物要么能够以短周期方法(Kurztaktverfahren)要么能够以持续方法(Durchlaufverfahren)与木材板压紧。
DE 100 35 924B4中描述了一种浸渍物和一种用于制造该浸渍物的方法。所谓的浸渍物通道作为工业设备被用于制造浸渍物。在这些浸渍物通道中,可以实现持续性制造,其方式是,使纤维素层运行经过一个或多个被填充以浸渍流体的盆。同样公开的是,浸渍流体通过辊和刮刀施加或通过喷嘴喷上。仍处在湿润状态的纤维素层接下来直接经受干燥,以蒸发多余的水分和/或将溶剂蒸发至限定的剩余湿度,并获得干燥的、存储稳定的和可机械加工的浸渍物。在浸渍通道末端上,持续运行的浸渍物要么被切割成片,要么被卷绕成卷。
已知的基于三聚氰胺树脂的层压地板由于该涂层的原因是硬的,因此感觉是凉的并且在行走时会产生具有干扰性的室内噪音。
WO 2011/082491A1中描述了可水稀释的聚氨酯用以制造已浸渍的覆层、装饰纸、底衬和对层的用途。在两级过程中,首先进行芯浸渍并接下来进行再浸渍在此过程中,采用较昂贵的聚氨酯,这种聚氨酯约比三聚氰胺树脂昂贵了10至15个点。如果用这种方法制造覆层,则由此使浸渍物会昂贵了8至10个点。因为需要至少两个浸渍通道,因此该浸渍不能在每个浸渍设备上执行。此外,基于具有水性树脂的纸的产品线的浸渍或干燥会导致了膨胀和收缩,其程度与配方的水分含量和所使用的人造树脂相关。在所描述的专用浸渍方法中,必须采用特殊的人造树脂,由此,膨胀收缩行为与“正常的”三聚氰胺树脂浸渍存在偏差。尤其是在当使用浸渍物作为装饰纸时,如果在压紧时要制造出与装饰同步走向的结构(同步孔),则这会导致出问题,因为压板的压印通常被基于三聚氰胺浸渍的装饰生长(Dekorwachstum)设计。
现有技术存在如下缺点:
·昂贵
·技术上不都是可行的
·未知的纸生长(Papierwachstum)
尽管如此,始终存在对于层压体的大量需求,尤其是对于具有更暖的、更软的和声音上更不那么引人注意的涂层的地板层的需求。
基于该问题,应提出一种用于制造改善的浸渍物的方法,通过该方法能够改善开头提到的层压体。
发明内容
本发明的技术任务尤其是在于,如此变换本身已知的层压生产工艺,使得能够简单且可靠地制造出具有更暖的、更软的和声音上更不那么引人注意的涂层的层压体,并且这些层压体还能够容易地集成到现有生产流程中。此外,对于机械应力(如撞击或者磨损)的表现当然也不会变差,而是应尽可能地甚至得以改善。
用于解决该问题的根据类属的方法的特征在于,将具有异氰酸酯基成分的液态介质垫层至少施加到已芯浸渍的纤维素层的一侧(即其上侧和/或下侧)上。
异氰酸酯基(Isocyanatgruppen)是高反应性的。根据本发明的异氰酸酯基要么与纤维素层中α纤维素的OH基、与NH基、要么与纤维素层的芯浸渍结构的三聚氰胺树脂的羟甲基反应,并且由此导致了特别有效地锚定在已芯浸渍的纤维素层的表面上。在随后将浸渍物压紧在载体上形成层压体之后,这会形成涂层,该涂层在触觉上比三聚氰胺树脂层更暖且更软。在这样制造的地板层压体中,这还能减少室内噪音。对于机械应力(如撞击或磨损)的表现与传统涂层相比并未变差。
所述液态介质具有优选50%至60%固体成分,并且以水为溶剂。除了水之外,有机溶剂或者添加物也是可行的,譬如散凝剂、脱模剂、润湿剂、消泡剂。干燥该液态介质会形成垫层。
所述液态介质也可被设计成具有100%固体成分,作为热熔胶。热熔胶在施加到已芯浸渍的纤维素层之前被加热并熔化成液体。在接下来的固化中,形成一垫层(Schicht)。形成垫层的过程可通过主动冷却进行加速。热熔胶要么借助缝式喷孔(Schlitzdrüse)、要么通过喷涂施加进行施加。
为了提高浸渍物的耐磨性,抑制磨损颗粒(尤其是刚玉颗粒)优选要么被包含在液态介质中和/或要么在液态介质上优选在形成垫层之前被喷上。
优选地,液态介质或者热熔胶以50g/m2至300g/m2的量被施加。
在液态介质或者已再硬化的热熔胶制成的已干燥的垫层上,能够在上侧上施加至少一个由UV漆组成的覆盖垫层,在所述覆盖垫层中也可混合入纳米颗粒,用以进一步改善抗微刮性。同样也可以混合有抗静电作用制剂和/或此外抗菌作用制剂。
所述三聚氰胺树脂可以是纯的三聚氰胺树脂。但是优选地,所述三聚氰胺树脂作为由三聚氰胺树脂和尿素树脂组成的混合物构成。
所述浸渍物可被用作覆层、对层、装饰纸和底衬。在此,浸渍物可以是片材或卷材。
附图说明
下面借助一个附图进一步描述本发明。
唯一的附图示出具有纤维素层4的浸渍物,所述浸渍物可被用作装饰纸、覆层(Overlay)、对层(Gegenzug)和/或底衬(Underlay)。所述浸渍物可以是片材或卷材。
具体实施方式
纤维素层4在层芯处由纯三聚氰胺树脂(Melaminharz)或者由纯三聚氰胺树脂与尿素树脂(Harnstoffharz)组成的三聚氰胺树脂混合物进行浸润。为此,纤维素层4可进行盆浴(Wannenbad),或者树脂可被辊施加上或被喷上。在此,被证明特别有利的是通过喷涂(Anspülen)进行单侧浸渍。为了去除上侧和下侧O、U上多余的树脂量,纤维素层4可由刮刀进行刮销。在已浸润的纤维素层4被干燥成限定的剩余湿度之后,在其上侧O和其下侧U上不形成三聚氰胺树脂垫层3、5,而是使芯浸渍结构填满所述纤维素层4。
至少在纤维素层4的上侧O或者下侧U上施加了含有异氰酸酯基的液态介质。所述液态介质具有优选50%至60%固体成分,并且以水为溶剂。除了水之外,有机溶剂或者添加物也是可行的,譬如散凝剂、脱模剂、润湿剂、消泡剂。以50g/m2至300g/m2被施加的分散体(Dispersion)随后被干燥成垫层2。在干燥后,在垫层2的上侧O上施加由UV漆组成的覆盖垫层1。该UV漆优选包含基于硅酸的纳米颗粒7以提高抗微刮性。
为提高抗微刮性,所述液态介质可含有抑制磨损的颗粒6、尤其是刚玉颗粒(Korundpartikel),所述颗粒6要么在施加前被混合到该介质中,要么在施加后被撒布在上侧O或下侧U上。
替换于将液态介质作为分散体施加到纤维素层4的上侧O或下侧U上并随后主动地干燥,也可使用具有异氰酸酯基的热熔胶(热熔粘接剂)。与分散体一样,热熔胶也可以附加地施加到纤维素层4的下侧U上。热熔胶在施加前被加热、变成液态、并随后在冷却时自动地形成了具有异氰酸酯基的垫层2。在此,也可向热熔胶混合了抑制磨损的颗粒6(尤其是刚玉颗粒)或者在所述施加后撒布在液态热熔胶的上侧O上。
所施加的分散体或所施加的热熔胶的量约固定为50g/m2至300g/m2。除了纳米颗粒7之外,覆盖垫层1也可被给予抗静电作用制剂(antistatisch wirksame Mittel)和/或抗菌作用制剂(antibakteriell wirksame Mittel)。这些制剂同样可以被混合入到液态材料中或者在所述施加后被撒布到仍处于液态的垫层1上。
譬如,可使用Fa.Kleiberit名为PUR HC717.5的销售产品作为热熔胶。热熔胶或者已干燥的分散体中的异氰酸酯基具有反应性并与纤维素层4中的α纤维素的OH基和/或与被芯浸渍的纤维素层4的三聚氰胺树脂的羟甲基(Methylolgruppe)反应形成聚氨酯和/或与NH基反应形成脲衍生物(Harnstoffderivat)。也可行的是,与水反应生成胺类(Amin)并与自由的异氰酸酯基进一步反应生成脲衍生物(Harnstoffderivaten)。通过这种方式能够将已干燥的分散体或热熔胶固定在浸渍物上。由此,与传统的三聚氰胺树脂垫层相比,形成了更软的、却耐磨的、触觉上更暖的且声音上不那么引人注意的垫层2。
如果这种该浸渍物要被用作覆层,则可将该浸渍物在短周期压力机(Kurztaktpressen)上与传统的经三聚氰胺树脂浸渍的装饰纸和对层进行组合地压紧。为了使异氰酸酯基与纤维素层4中的三聚氰胺树脂和/或与纤维素层4中的α纤维素反应,可将各个垫层形成为复合结构,并且通过包含在纤维素层4中的三聚氰胺,使覆层与剩余的经三聚氰胺树脂浸渍的纸相连接。
实践表明,在比较试验中,具有三聚氰胺覆层的产品与具有根据本发明的覆层的产品之间没有颜色偏差。
纤维素层4可以是纸、尤其是已印刷的装饰纸。在后续将层压结构压紧的过程中,可将与装饰同步的结构(同步孔)压入到覆盖垫层1中。被刻有这种结构的、通常被设计用于由三聚氰胺树脂组成的结构的压板可不经更改地被使用。
这样制造的浸渍物可与木材板(譬如MDF或HDF板)、其它浸渍物和尤其是专用纸或者硬纸一起压紧形成为层压体。
尤其是可使用被涂层有一个或多个浸渍物的木材板来制造如下地板嵌板(Fuβbodenpaneele):该地板嵌板在相对置的侧棱边上被这样地轮廓化,使得多个嵌板能够相互连接且相对彼此锁定。
附图标记列表
1 UV漆组成的覆盖垫层
2 介质垫层
4 以三聚氰胺树脂进行芯浸渍的纤维素层
6 耐磨颗粒
7 纳米颗粒
O 上侧
U 下侧
Claims (13)
1.一种用于制造具有纤维素层(4)的浸渍物的方法,所述纤维素层以三聚氰胺树脂浸渍,用于构成芯浸渍结构,
其特征在于,将由具有异氰酸酯基成分的液态介质组成的垫层(2)施加到已芯浸渍的纤维素层(4)的上侧(O)和/或下侧(U)上。
2.根据权利要求1所述的方法,其特征在于,所述液态介质作为如下分散体被施加并且随后被干燥成一垫层,所述分散体具有50%至60%的固体成分并且剩余为水分。
3.根据权利要求1所述的方法,其特征在于,
所述液态介质作为经加热的热熔胶被施加并且在随后冷却时自动地形成一垫层,所述热熔胶具有100%固体成分。
4.根据权利要求1至3中任一项所述的方法,其特征在于,在所述介质中含有抑制磨损的颗粒(6)、尤其是刚玉颗粒。
5.根据前述权利要求中任一项所述的方法,其特征在于,所述介质的量为50g/m2至300g/m2。
6.根据前述权利要求中任一项所述的方法,其特征在于,将至少一个覆盖垫层(1)施加到所述上侧(O)上的所述垫层(2)上。
7.根据权利要求6所述的方法,其特征在于:
所述覆盖垫层(1)具有纳米颗粒(7),以改善抗微刮性,和/或
设置抗静电作用制剂和/或抗菌作用制剂。
8.根据权利要求1所述的方法,其特征在于,将所述三聚氰胺树脂构成为由三聚氰胺树脂与尿素树脂组成的混合物。
9.一种浸渍物,该浸渍物根据前述权利要求中任一项所述的方法制造,用以在制造层压体时使用。
10.一种用于制造层压体的浸渍物,该浸渍物具有纤维素层(4),所述纤维素层以三聚氰胺树脂浸渍,用于构成芯浸渍结构,其特征在于,将由具有异氰酸酯基成分的液态介质组成的垫层(2)施加在已芯浸渍的纤维素层(4)的上侧(O)和/或下侧(U)上。
11.根据权利要求9或10所述的浸渍物,其特征在于,所述浸渍物被用作覆层、对层、装饰纸或者底衬。
12.根据权利要求9或10所述的浸渍物,其特征在于,所述浸渍物是片材或者卷材。
13.一种层压体,具有至少一个根据权利要求1至8中任一项所述的方法制造的浸渍物。
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EP14002167.6A EP2960369A1 (de) | 2014-06-24 | 2014-06-24 | Verfahren zur Laminatherstellung |
EP14002167.6 | 2014-06-24 | ||
PCT/EP2015/001195 WO2015197164A1 (de) | 2014-06-24 | 2015-06-15 | Verfahren zur laminatherstellung |
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CN108624242A (zh) * | 2018-05-23 | 2018-10-09 | 广东鹏美森木业科技有限公司 | 一种瓷砖快速粘贴胶及其制作方法 |
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EP3686008B1 (de) * | 2019-01-23 | 2021-06-23 | Flooring Technologies Ltd. | Verfahren zur herstellung eines abrieb- und wasserfesten mehrlagigen paneels und ein mit diesem verfahren hergestelltes paneel |
PL3702172T3 (pl) * | 2019-03-01 | 2022-08-16 | Flooring Technologies Ltd. | Sposób produkcji wielowarstwowego panelu o powierzchni strukturyzowanej oraz panel produkowany tym sposobem |
CN112982033A (zh) * | 2021-03-22 | 2021-06-18 | 佛山市西钢装饰材料有限公司 | 一种复合三聚氰胺纸的卷材 |
BE1029240B1 (nl) * | 2021-03-24 | 2022-10-24 | Flooring Ind Ltd Sarl | Panelen en methode om panelen te produceren |
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US10385512B2 (en) | 2019-08-20 |
UA121466C2 (uk) | 2020-06-10 |
RU2016138723A (ru) | 2018-07-24 |
RU2016138723A3 (zh) | 2018-11-06 |
CA2947058C (en) | 2023-10-03 |
RU2691045C2 (ru) | 2019-06-07 |
EP2960369A1 (de) | 2015-12-30 |
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WO2015197164A1 (de) | 2015-12-30 |
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