DE102007046237A1 - Process for the production of coating elements and related manufacturing equipment - Google Patents

Abstract

In order to provide a method for producing at least one coating element, in particular at least one decorative layer suitable for coating at least one carrier plate (60), wherein - by unwinding raw fiber material or raw paper, in particular raw decor paper, at least one fiber material or paper web (50) is clamped, and the spanned fiber material or paper web (50) is at least partially printed with color and / or at least one pattern or decor, as well as a related manufacturing device (100) educate so that the Beschichtungselment can be efficiently prepared, with kinks, cracks or shape changes the printed fiber material or paper to be reliably avoided, it is proposed that the spanned fiber material or paper web (50) after printing at least partially - with at least one resin, in particular with at least one aminoplastic and / or thermosetting Kunsth is impregnated, for example, with melamine resin, and / or - with at least one at least one resin, in particular at least one aminoplastic and / or thermosetting synthetic resin, for example melamine resin having layer is coated.

Description

Technical area

The The present invention relates to a method according to the Preamble of claim 1.

The The present invention further relates to a manufacturing device according to the preamble of claim 5.

State of the art

laminate is a laminate pressed by pressing, gluing and / or Gluing at least two layers of the same and / or different Material is formed.

One Laminate, for example, as a floor, as wall or Ceiling covering, as a worktop or for furniture production can be used, has at least one support plate on, with at least one coating element, in particular with at least one decorative layer of decorative paper and thermosetting Resin, coated.

When Support plate is usually a wood-based panel, for example a fiberboard, such as a high density fiberboard (HDF) or a medium-density fiberboard (MDF), or a chipboard or a wood-based panel of oriented, scattered microforms, a so-called O [riented] S [trand] B [oard].

decisive for the optical appearance of the laminate is the decorative layer, which is applied to the top of the carrier plate. The decor paper of the decorative layer may be colored and / or patterned or decor, for example, with a wood or stone reproduction, be printed.

to Improving the durability of the laminate will the decorative paper usually with thermosetting Synthetic resin, impregnated, for example, with melamine resin and / or with an abrasion-resistant layer, the so-called overlay, beschichtetet.

The Overlay has thermosetting resin, for example Melamine resin, on. For improved resin absorption, the overlay furthermore fiber-containing, in particular cellulose-containing, material exhibit. This fibrous resin layer can further improve their abrasion resistance with abrasion-resistant or abrasive substances, For example, be provided with corundum particles. For example The overlay can be made of two transparent melamine resin soaked There are papers between which a corundum layer is enclosed is. Furthermore, corundum filled overlays are common.

On the carrier plate facing side of the coating element may be a core or backing paper layer of several with thermosetting resin, for example with phenolic resin, be arranged impregnated papers. This optional Paper layer, preferably used as paper kraft paper becomes, gives the coating element additional hardness and impact resistance and improves its staying power.

to Improvement of the dimensional stability of the laminate element can the underside of the backing plate with a so-called Backing, for example with a veneer or with another impregnated with thermosetting resin Layer, be pressed.

at A distinction is made between one-stage and one-off laminate production two-stage production process. In the single-stage production process are the different layers, so the decorative layer of decorative paper and thermosetting resin, the z. B. in shape an overlay may be applied to the decorative paper, the support plate and the optional return in one operation directly to the so-called directly pressed laminate (D [irect] P [ressure] L [aminate]) with each other pressed.

In the two-stage process, however, in a first step from the decorative paper and the thermosetting resin, z. B. may be applied in the form of an overlay on the decorative paper, and the optional core or backing paper layer provides a coating element Herge. In a second step, the coating element is then pressed with the carrier plate. These laminate manufacturing processes are in the DIN standards DIN EN 14322 . DIN EN 438-2 and DIN EN 13329 described. With regard to the technical background of the laminate production is further on the document WO 2007/079547 A1 Referenced.

at the known laminate production method is the decorative layer made of decorative paper and thermosetting synthetic resin in two separate operations on two separate production lines. First, the decorative paper is on a first production line printed, the printing is usually done in gravure printing. Afterwards, the printed decorative paper is rolled up again and for impregnating or for coating with thermosetting Resin transported to a second manufacturing plant. On the second Production plant will then print the printed paper in a second Operation or second method with the thermosetting Resin impregnated and / or coated with the overlay.

The Production of the decorative layer on two separate production lines However, in two separate manufacturing processes is less efficient, because transported the raw decor paper to two different production facilities and each must be inserted in this. So it will be in the first production line for printing the paper a first paper web made of raw paper and used in the second production line for Impregnate or for coating the paper a second Paper web stretched out of printed paper. This production method is time consuming and thus costly. Also need two separate production plants relatively much stand.

One Another disadvantage is that twice clamping the paper web to a change in the shape of the decorative paper and thus distortion or distortion of the printed design; and lead to buckling and / or tearing the decorative paper can.

In the publication DE 600 15 603 T2 In order to avoid fitting inaccuracies of the pattern of a laminate floor, it is proposed to print this pattern by means of a digital printer directly onto the carrier plate, ie, for example, directly onto the wood-based panel. However, this has the disadvantage that the surface of the support plate treated before printing, for example, primed and / or sanded. In addition, in the laminate element according to the document DE 600 15 603 T2 only transparent layers are applied to the carrier plate. It is thus not possible, for example, to apply a core or carrier paper layer of kraft pulp to the carrier plate.

Illustration of the present invention: Task, solution, benefits

outgoing from the disadvantages and shortcomings set out above and in appreciation of the state of the art outlined The present invention is based on the object, a method of the aforementioned type and a manufacturing device of initially developed type so that the coating element efficiently can be made, with kinks, cracks or shape changes the printed fiber material or paper reliable be avoided.

These The object is achieved by a method with the specified in claim 1 Characteristics and by a manufacturing plant with the in the claim 5 specified characteristics solved. Advantageous embodiments and expedient developments of the present Invention are characterized in the respective subclaims.

The The present invention is basically based on a In-line production equipment, such as an in-line production line, to design, in which the fiber material or paper in a first Printed step and then immediately by impregnation and / or Coating is further processed. According to the The present invention is thus in a production process the printed fiber material or paper printed and then impregnated and / or coated in the same production process.

• – mit mindestens einem Harz, insbesondere mit mindestens einem aminoplastischen und/oder wärmehärtbaren Kunstharz, beispielsweise mit Melamin-Harz, imprägniert und/oder
• – mit mindestens einer mindestens ein Harz, insbesondere mindestens ein aminoplastisches und/oder wärmehärtbares Kunstharz, beispielsweise Melamin-Harz, aufweisenden Schicht, etwa mit einem so genanten Overlay, beschichtet.

According to the invention, for producing at least one coating element, in particular for producing at least one fibrous material and resin suitable for coating at least one carrier plate, in particular decor paper and aminoplastic and / or thermosetting synthetic resin, first by unwinding raw fiber material or base paper, in particular raw decor paper , Spanned at least one fiber material or paper web. This stretched fiber material or paper web is then at least partially printed with color and / or with at least one pattern or decor. Subsequently, the spanned and printed fiber material or paper web is at least partially

• - impregnated with at least one resin, in particular with at least one aminoplastic and / or thermosetting synthetic resin, for example with melamine resin, and / or
• - Coated with at least one at least one resin, in particular at least one aminoplastic and / or thermosetting resin, such as melamine resin, having layer, such as with a so-called overlay.

The Combination of printing and impregnating and / or coating in a manufacturing facility or in a machine can be realized be by at least one impregnating and / or coating device arranged in series or inline with at least one printing device becomes. For example, the printing device between at least one designed to unwind the fiber material or paper web Unwinding device and a first dip or a first Coating device of the impregnating and / or coating device be arranged. Unwinding device, printing device and impregnating and / or Coating device are therefore preferably in series, for example on at least one production line or production line, about at least one impregnation, arranged.

According to an advantageous embodiment of the present invention, the manufacturing device comprises the components of a conventional impregnating and / or coating device. However, these components are arranged so that the stretched fiber material or paper web can be both printed as well as impregnated and / or coated.

The Printing the fiber material or paper web can by means of the method the gravure printing or by the method of digital printing. The Application of the method of digital printing is particularly advantageous because a digital printing device has a small footprint and thus easily integrated into conventional impregnation machines can be. In addition, requires a digital printing device or a digital printing unit no costly printing forms. Further Advantages of a digital printing device compared to a gravure printing device are lower investment costs and the possibility simpler and cheaper decor change. In addition, you can Reduced storage costs in the raw materials area by means of a digital printing device because no large number of decors are kept needs.

According to one advantageous embodiment of the present invention Thus, the fiber material or paper web by means of at least a digital printing device printed. This digital printing device meets the requirements for printing the fiber material or paper web required properties and is preferred designed to substantially cover the entire width of the fiber material or paper web to print.

Vorteihafterweise is the digital printing device designed to the printed fiber material or Dry paper web at least partially. The drying of the fiber material or paper web can be air and / or Ultra Violet radiation and / or by means of the method of near-infrared drying. In addition to pure air drying so can other drying methods such For example, UV drying and / or NIR drying are used.

A advantageous embodiment of the printing device has due to a comparatively low printing speed a comparatively short, for example, a few meters amount, drying section on.

• – mindestens ein Harz, insbesondere mindestens ein aminoplastisches und/oder wärmehärtbares Kunstharz, beispielsweise Melamin-Harz, und/oder
• – Fasermaterial, insbesondere Zellstoff, und/oder
• – mindestens eine abriebfeste Substanz, insbesondere Korund, aufweisenden Schicht versehen werden.

After passing through the printing device or the printing unit, the known impregnation and / or coating process can continue unchanged. For example, the stretched fiber material or paper web can be impregnated or impregnated with at least one resin, in particular with at least one aminoplastic and / or thermosetting synthetic resin, for example with melamine resin, and impregnated with at least one after impregnation or impregnation.

• At least one resin, in particular at least one aminoplastic and / or thermosetting synthetic resin, for example melamine resin, and / or
• - Fiber material, in particular pulp, and / or
• - Are provided at least one abrasion-resistant substance, in particular corundum, having layer.

Of Furthermore, the clamped fiber material or paper web, in particular on its side facing away from the resin layer, with at least a core or backing paper layer are coated, wherein the core or backing paper layer is at least one with thermosetting synthetic resin, for example with Phenolic resin, impregnated fiber material, in particular paper, For example, kraft paper has.

• – mindestens ein Beschichtungselement nach einem Verfahren gemäß der vorstehend dargelegten Art hergestellt und
• – anschließend auf mindestens eine Trägerplatte aufgebracht, insbesondere aufgeleimt und/oder aufgeklebt und/oder aufgepresst.

The present invention further relates to a method for the production of laminate, for example of at least one laminate floor element, at least one laminate worktop, at least one wall or ceiling cladding element of laminate or at least one laminate furniture element, and a device relating thereto. In this case, the production of laminate according to the invention

• - Produced at least one coating element by a method according to the manner set forth above and
• - Then applied to at least one support plate, in particular glued and / or glued and / or pressed.

According to one advantageous development of the invention Process for producing a coating element and the Manufacturing device according to the invention can thus the spanned fiber material or paper web of the coating element also the same, ie in the same production process, on the carrier plate, For example, on a wood-based panel, such as an MDF, HDF, OSB or chipboard, or on a plastic plate applied become.

Furthermore, the support plate on its side facing away from the coating element can still be coated in the same production process with at least one counter-pull, for example with at least one veneer and / or with at least one further thermosetting synthetic resin layer. The coating element can be laminated to the carrier plate by means of a single-stage or by means of a two-stage process. From the coating element produced according to the invention, it is thus possible to use both D [irect] P ressure L [aminate] as H [igh] P ressure L [aminate] and C [ontinuous] P ressure L [aminate] as well as L [ow] P [ressure] L [aminate] become.

• – zur Inline-Fertigung bzw. Reihenfertigung von bedrucktem, imprägniertem und/oder beschichtetem Dekorpapier und/oder
• – zur Inline-Fertigung bzw. Reihenfertigung von Laminat, insbesondere mittels eines Verfahrens zur Herstellung von Laminat der vorstehend dargelegten Art und/oder mittels mindestens einer Vorrichtung zur Herstellung von Laminat gemäß der vorstehend dargelegten Art.

Finally, the present invention relates to the use of a method for producing at least one coating element according to the type set forth above and / or at least one production device according to the type set forth above

• - For in-line production or series production of printed, impregnated and / or coated decor paper and / or
• For the in-line production or serial production of laminate, in particular by means of a method for the production of laminate of the kind set forth above and / or by means of at least one device for the production of laminate according to the kind set forth above.

Brief description of the drawings

As already discussed above, there are various possibilities for embodying and developing the teaching of the present invention in an advantageous manner. For this purpose, reference is made on the one hand to the claims subordinate to claim 1 and claim 5, on the other hand further embodiments, features and advantages of the present invention will be described below with reference to 1 illustrated embodiment explained in more detail.

1 Fig. 1 shows a schematic representation of a first embodiment of a device according to the present invention, which operates according to the method of manufacturing laminate according to the present invention.

Best way to execute of the present invention

• – ein Ausführungsbeispiel einer Fertigungseinrichtung 100 zur Herstellung mindestens eines Beschichtungselements gemäß der vorliegenden Erfindung, wobei die Fertigungseinrichtung 100 nach dem Verfahren zur Herstellung mindestens eines Beschichtungselements gemäß der vorliegenden Erfindung arbeitet und
• – eine zum Aufbringen des Beschichtungselements, insbesondere der aufgespannten, bedruckten, imprägnierten und/oder beschichteten Fasermaterial- oder Papierbahn 50, auf eine Trägerplatte 60 ausgebildete Laminiereinrichtung 210.

I'm referring 1 illustrated first embodiment of the present invention is a device 200. in particular an in-line production line, for the production of laminate, which operates according to the method according to the present invention and has a plurality of functional parts, namely

• - An embodiment of a manufacturing facility 100 for producing at least one coating element according to the present invention, wherein the production device 100 according to the method for producing at least one coating element according to the present invention operates and
• - One for applying the coating element, in particular the spanned, printed, impregnated and / or coated fiber material or paper web 50 , on a carrier plate 60 trained laminator 210 ,

The manufacturing facility 100 is for preparing a for coating the carrier plate 60 formed suitable decorative layer, wherein the decorative layer has at least printed decorative paper and thermosetting resin.

• – eine zum Aufspannen mindestens einer Fasermaterial- oder Papierbahn 50 mittels Abwickeln von Rohfasermaterial oder von Rohpapier, insbesondere von Rohdekorpapier, ausgebildete Abwickeleinrichtung 10,
• – eine zum Bedrucken der aufgespannten Fasermaterial- oder Papierbahn 50 mit Farbe und/oder mindestens einem Muster bzw. Dekor ausgebildete Druckeinrichtung 20 und
• – eine in Reihe bzw. inline mit der Druckeinrichtung 20 angeordndete Imprägnier- und/oder Beschichtungseinrichtung 30, nämlich eine Imprägniereinrichtung 30, auf.

For this purpose, the manufacturing facility 100

• - One for clamping at least one fiber material or paper web 50 by unwinding of raw fiber material or raw paper, in particular raw decor paper, unwinding device formed 10 .
• - One for printing the clamped fiber material or paper web 50 formed with color and / or at least one pattern or decor printing device 20 and
• - One in series or inline with the printing device 20 arranged impregnating and / or coating device 30 namely, an impregnation device 30 , on.

This impregnation device 30 is for impregnating the clamped fiber material or paper web 50 with aminoplastic and thermosetting resin, namely with melamine resin. Furthermore, the impregnating device could 30 also for coating the clamped fiber material or paper web 50 be formed with a resin, in particular melamine resin, having layer, ie with an overlay.

Im in 1 illustrated embodiment, the manufacturing device 100 however, for coating the stretched fiber material or paper web 50 with the overlay one in series or inline with the impregnation device 30 arranged coating device 40 on.

The printing device 20 is between the unwinding device 10 and the impregnation device 30 arranged and for printing the fiber material or paper web 50 formed by the method of digital printing.

For at least partial drying of the printed fiber material or paper web 50 has the printing device 20 a drying device 22 on. Alternatively (in 1 not shown), this drying device 22 also in series or inline with the printing device 20 and the impregnation device 30 , in particular between the printing device 20 and the impregnation device 30 to be arranged.

In contrast to the known from the prior art and practiced methods in which in two separate operations only decorative paper usually printed by gravure printing and then impregnated on another system in a second method, which leads in 1 gezeig te manufacturing facility 100 an inline method for printing and impregnating and / or coating decorative paper. The new is neither the printing itself, nor the impregnation and / or coating, but the fact that this is done inline during a single operation, ie on a manufacturing facility or machine.

10

unwinding

20

Printing means, especially digital printers or gravure printers

22

drying device

30

impregnating and / or coating device

40

coater

50

fiber material or paper web

60

Support plate in particular wood-based or plastic board

100

Manufacturing facility or manufacturing plant, in particular in-line production line for producing a coating element, in particular for producing a for coating a carrier plate 60 suitable decorative layer

200

Contraption, especially inline production line for the production of laminate

210

laminating

QUOTES INCLUDE IN THE DESCRIPTION

This list The documents listed by the applicant have been automated generated and is solely for better information recorded by the reader. The list is not part of the German Patent or utility model application. The DPMA takes over no liability for any errors or omissions.

Cited patent literature

• WO 2007/079547 A1 [0012]
• - DE 60015603 T2 [0016, 0016]

Cited non-patent literature

• - DIN EN 14322 [0012]
• - DIN EN 438-2 [0012]
• - DIN EN 13329 [0012]

Claims (10)

Method for producing at least one coating element, in particular at least one for coating at least one carrier plate ( 60 ) suitable decorative layer, wherein - by unwinding of raw fiber material or raw paper, in particular of raw decorative paper, at least one fiber material or paper web ( 50 ) is clamped and - the clamped fiber material or paper web ( 50 ) is at least partially printed with color and / or with at least one pattern or decor, characterized in that the spanned fiber material or paper web ( 50 ) in particular in an in-line process, after printing at least partially - impregnated with at least one resin, in particular with at least one aminoplastic and / or thermosetting synthetic resin, for example with melamine resin, and / or - with at least one at least one resin, in particular at least one aminoplastic and / or thermosetting synthetic resin, for example melamine resin, containing layer is coated. A method according to claim 1, characterized in that the clamped fiber material or paper web ( 50 ) is at least partially dried after printing and before impregnation, wherein the drying of the fiber material or paper web ( 50 ) in particular - by means of air and / or - by means of Ultra Violet radiation and / or - by means of the method of near-infrared drying. A method according to claim 1 or 2, characterized in that the printing of the fiber material or paper web ( 50 ) by means of the method of digital printing or gravure printing. Process for producing laminate, characterized in that - at least one coating element is produced by a process according to at least one of claims 1 to 3 and - that subsequently the coating element, in particular the stretched, printed, impregnated and / or coated fiber material or paper web ( 50 ), on at least one support plate ( 60 ), in particular glued and / or glued and / or pressed, is. Manufacturing facility ( 100 ) for producing at least one coating element, in particular at least one for coating at least one carrier plate ( 60 ) suitable decorative layer, comprising - at least one for clamping at least one fiber material or paper web ( 50 ) by unwinding of raw fiber material or raw paper, in particular raw decor paper, unwinding device ( 10 ) and - at least one for at least partially printing the clamped fiber material or paper web ( 50 ) with color and / or at least one pattern or decor formed printing device ( 20 ), characterized by at least one impregnating and / or coating device ( 30 ) in series with the printing device ( 20 ) is arranged and - for at least partially impregnating the clamped fiber material or paper web ( 50 ) with at least one resin, in particular with at least one aminoplastic and / or thermosetting synthetic resin, for example with melamine resin, and / or - for at least partial coating of the stretched fiber material or paper web ( 50 ) is formed with at least one resin, in particular with at least one aminoplastic and / or thermosetting synthetic resin, for example with melamine resin. Manufacturing device according to claim 5, characterized in that the printing device ( 20 ) - between the unwinding device ( 10 ) and the impregnating and / or coating device ( 30 ) is arranged and / or - is adapted to the fiber material or paper web ( 50 ) by means of the method of digital printing or by the method of intaglio printing. Manufacturing device according to claim 5 or 6, characterized by at least one - the printing device ( 20 ) or - in series with the printing device ( 20 ) and the impregnating and / or coating device ( 30 ), in particular between the printing device ( 20 ) and the impregnating and / or coating device ( 30 ), arranged drying device ( 22 ) for at least partially drying the fiber material or paper web ( 50 ) in particular by means of - air and / or - ultra violet radiation and / or - the method of near-infrared drying. Manufacturing device according to at least one of claims 5 to 7, characterized in that the resin-containing layer further - fiber material, in particular pulp, and / or - at least one abrasion-resistant or abrasive substance, in particular corundum, having. Contraption ( 200. ) for producing a laminate, characterized by - at least one production device ( 100 ) according to at least one of claims 5 to 8 and - at least one for applying the coating element, in particular the spanned, printed, impregnated and / or coated fiber material or paper web ( 50 ), on at least one support plate ( 60 ) formed laminating device ( 210 ). Use of a method for producing at least one coating element according to at least one of claims 1 to 3 and / or at least one production device ( 100 ) according to any one of claims 5 to 8 - for inline production or series production of printed, impregnated and / or coated decor paper and / or - for inline production or series production of laminate, in particular by means of a method for producing laminate according to claim 4 and / or at least one device ( 200. ) for the production of laminate according to claim 9.