DE19830778C1 - Laminated sheet comprising base and decorative layers, intended for hot post-forming - Google Patents

Abstract

Below the sheet laminate, into the base layer (103) a longitudinal, shallow-curved concave groove (104) is produced. This will form a bending zone, when later making a rounded edge. An Independent claim is included for the corresponding method of manufacture. Preferred features: A curved edge of radius of 3 mm \! 10% will subsequently be formed, which is independent of sheet thickness. At the center of the concave groove (104) the residual thickness (DR) is 0.3 mm. Spacing between outer edges (106, 107) of the groove is 7 mm \! 3%. The groove is made symmetrically about its length in the laminated sheet. High pressure laminate (HPL) is used, the total thickness being 0.6-1.3 mm. The laminate is adhered to a supportive base slab (e.g. a work surface) using an adhesive. A rounded top corner is formed over the edge of the slab, along the location of the concave groove in the laminate.

Description

The invention relates to a decorative laminate with a base layer and a decorative layer that is warm is deformable.

Furthermore, the invention is concerned with a method for Manufacture a composite panel from a decorative Laminate according to one of claims 1 to 6 and a rigid carrier plate by means of an adhesive, wherein on the carrier plate at least two over a rounded Corners abutting sides with a small outer radius a continuous laminate using the Adhesive adherent with formation of a bending edge an outer diameter less than 5 mm is applied.

Decorative laminated sheets based on aminoplast resin are known and are used in particular for the production of Composite panels using rigid carrier panels used to high decorative surfaces Abrasion resistance, high shock resistance, high scratch resistance especially for the furniture industry, kitchen fronts, To create wall coverings, table tops, etc.

The present invention is particularly concerned with the so-called high-pressure laminates (HPL - high pressure laminates), which are produced with cover layers based on melamine resin and several core layers based on phenolic resin, pressed at a pressure of at least 7 N / mm ² .

Decorative HPL-quality laminated panels are produced in multi-daylight presses at a temperature of 130 to 160 ° C and a pressure of 7 N / mm ² , usually approx. 10 N / mm ² , in plate thicknesses of usually 0.5 to 1 , 3 mm. The structure of decorative laminated panels is usually as follows:

• 1. Overlay paper made from bleached noble sulfate pulp without pigments, impregnated with melamine resin, resin content usually between 65 to 80%, basis weight 17 to 50 g / m ² as a scratch-resistant and mostly high-gloss surface layer,
• 2. Decorative paper made from bleached noble sulfate pulp dyed in the mass or with color printing to cover the base layer, provided with fillers, impregnated with melamine resin, resin content usually between 40 to 45%, basis weight 75 to 130 g / m ² .
  The layer 1 - overlay paper - and the layer 2 - decorative paper - can also be combined in such a way that a separate overlay paper is omitted and only the decorative paper is provided, but then with a higher resin content and higher basis weight, in order also to to form a transparent, abrasion-resistant, shockproof, possibly high-gloss surface,
• 3. optionally an underlay paper or barrier paper below the decorative paper, which is also impregnated with melamine urea resin with a resin content of 45 to 50% and can have a weight per unit area of 80 to 100 g / m ² .
• 4. Base layer of core papers made of unbleached sulfide pulp, soaked with phenolic resin, resin content approx. 30%, basis weights between 150 to 250 g / m ² .

The decor papers are dyed in any color or with multicolor printing abstract as in Patterned natural product replicas that surfaces can embossed smooth, satin or structured.

The overlay papers, which are sometimes omitted, become transparent when pressed and thus deepen the Color effect of the decor and reinforce the Wear protection layer.

HPL plates, i. H. decorative laminated panels in HPL Quality, are standardized according to DIN 16926 and in different Types divided.

Type N corresponds to a normal quality and type P corresponds to one postforming quality. These are decorative Laminates, which at certain from the respective Manufacturer can be post-deformed temperature.

Due to the qualities of the decorative Laminates in HPL quality and postforming Quality can be used to form rounded corners like this is often required for furniture components and panels can be post-formed warm, but only with bending radii of usually ten times the thickness of those used Laminated sheets. Because the decorative Laminates usually on carrier boards laminated or with these adherent by means of adhesives connected, result in these composite building boards relatively large rounded corners, often considered disadvantageous are felt and also when they are joined together of two composite building boards with correspondingly rounded corners lead to very large visible gaps. Such large visible gaps  are visually disturbing on the one hand, further reduce the active level user interface.

The invention is based, which in the Processing of decorative laminated panels so far limited opportunities to create rounded corners to improve with smaller bending radii, with outer radii for decorative laminates in HPL quality of about 3 mm should be realized without the Functionality and quality in the bending area of the corner suffers and the quality of the surface, in particular High-gloss surface qualities are retained.

According to the invention, this task is for decorative Laminates of the generic type thereby solved that on the underside of the laminate in Area of the base layer along a bending edge to be formed a concave recess viewed in cross section milled is.

It is already known for thick materials, both elastic as well as rigid, with corners under deformation are trained to cut material in the corner areas, usually in wedge shape.

The proposal according to the invention deviates significantly from this, because it provides a concave recess, which in the decorative laminated sheets in question here is only formed inside the base layer Leave one more in the largest area of the recess Residual thickness of both the base layer and the complete one Preservation of the decorative layer of the laminate.

Advantageous further developments of the decorative Laminate are the distinguishing features of Subclaims 2 to 5 can be removed.  

A preferred training of the decorative Laminated sheet sees the formation of corners with one Outside radius of 3 mm. The decorative Laminate board is characterized according to the invention from that to form a bending edge with an outer radius of 3 mm with a tolerance of +/- 10% regardless of the Thickness of the laminate in the middle of the concave Recess a residual thickness of 0.3 mm is provided and the Distance between the outer edges of the concave recess 7 mm +/- a tolerance of 3%.

The concave recess is preferred for forming the Bending edge and the rounded corner in the decorative Laminated sheet symmetrical to its length formed in the base layer. A preferred one Fields of application of the invention are decorative Laminates, which are called high-pressure laminates Qualities type N and type P (postforming quality) trained are and have a total thickness of 0.6 to 1.3 mm.

In a further development of the laminated sheet according to the invention are made using the same composite panels, prefers those where the decorative Laminate with a support plate by means of a Adhesive to form a rounded corner lengthways the assigned to the area of the concave recess Bending edge is connected. Here, carrier plates are based of wood-based materials, such as chipboard, medium density Fiberboard or the like preferred. The composite panels can be used as surface elements, wall elements, table tops or the like in particular in the furniture industry and Manufacture of interior panels can be used. The Connect the decorative laminate with Carrier plates by means of an adhesive is in the Furniture industry known.

The invention enables for decorative Laminates in HPL quality and postforming  Quality of all marketable deformable laminates in Thicknesses from 0.6 to 1.3 mm and different surface from matt, structured to high gloss including metallic Surfaces, such as aluminum and steel, all of these commercially available base plates or base materials based of common wood-based materials and pressed with Deform bending edges, the bending edges with a small outside radius of 3 mm with a tolerance of +/- 0.3 mm can be trained.

According to the invention, regardless of the thickness of the decorative Laminated sheet from 0.6 to 1.3 mm Laminated sheet from the bottom inside Base layer and within the deformation area by means of a milling cutter with a concave cross section trained in the longitudinal extent of the later bending edge runs. This leaves the area in the middle Recess, i.e. the largest area of the recess, always receive a residual thickness of the laminated sheet of 0.3 mm. Between the center and the two outside of the concave recess, the distance is 3.5 mm, d. H. a total of 7 mm, with small manufacturing tolerances in purchase be taken.

The invention further relates to a method for Manufacture of composite building boards using decorative laminated sheets for the formation of Composite panels with rounded bending edges of the decorative Laminates with very small outer radii, preferably below 5 mm, in particular in the range of 3 mm.

The process according to the invention for producing outer radii of bending edges of decorative laminate sheets in HPL quality, which are hot-deformable, is characterized in that

• a) on the underside of the laminate a Cross section viewed in a concave recess  later bending edge forming direction within the Area of the base layer is milled,
• b) on the carrier plate corresponding to the bending edge Edge is rounded,
• c) and the areas of the Laminate and the carrier plate with the Adhesives are coated, provided they are not already were previously equipped with the adhesive,
• d) then the laminate on the larger Contact surface of the carrier plate is applied and the edge strips protruding from this contact surface Laminated sheet including the concave The recess is heated so far that the edge strip using pressure to contact the Carrier plate forming a rounded corner is deformed.

With the composite panel that can be produced according to the invention with a decorative laminate as a surface layer it is possible for the first time with such HPL laminates To produce bending radii in the range of 3 mm outer radius and to form very small visible joints or edges rounded off with very small outer radii like it hitherto particularly in the case of laminated panels with high-gloss or metallic surface layers was not possible.

Advantageous further developments of the method according to the invention are the characterizing features of subclaims 7 to 10 removable.

The method according to the invention is for the production of Bending edges with 3 mm outer radius of the decorative Laminated sheets while maintaining the quality of the Surfaces, especially with high gloss surfaces and metallic surfaces in such a way that the  Form a bending edge with an outer radius of 3 mm with a tolerance of +/- 10% regardless of the thickness of the Laminate a concave recess with a Remaining thickness of 0.3 mm in the middle of the concave recess the laminate and with a distance between the Outer edges of the concave recess remaining distance from 7 mm +/- 3% tolerance is milled and on the carrier plate a rounded corner with a smaller one by the remaining thickness Outside radius is formed.

The decorative laminated sheets come with the number the bending edges for the respective composite product corresponding number of concave in cross section Recesses in the direction of those to be produced later Bending edges run, provided. Especially for the Manufacture of composite panels in the form of panels the tailor-made decorative Laminates with two parallel to each other provided concave recesses, which creates panels can be produced with very small rounded corners, which then with later use of the panels for the production of Wall cladding for very small visible joints in the run lined up panels.

Milling and machining the decorative Laminated sheets to make the concave Recesses corresponding to the later bending edges and The corresponding roundings are made using Concave milling machines with a corresponding Carbide saw blade are equipped.

The invention is described below with reference to the drawing exemplified.

Show it

Fig. 1 is a decorative laminate with a concave recess, in part

Fig. 2 is a decorative laminate in side view, in part

Fig. 3 is a carrier plate in side view, in part

Fig. 4 is a composite panel with decorative laminate and carrier plate in side view, in part

Fig. 5 diagrammatically shows an intermediate stage of manufacture of a composite panel with the products according to Figs. 1 and 3

Fig. 6 is a side view of a composite panel in panel form

Fig. 7 is a visible gap between two panels according to FIG. 6 in a partial side view.

FIG. 2 schematically shows a decorative laminate 10 , which is designed as an HPL laminate and has a base layer 103 with a decorative layer 102 on one side with a scratch-resistant, high-gloss surface 101 .

In order to not only form butted corners with multi-sided cladding of the carrier plate, but also rounded edges over which the decorative laminate plate passes, when laminating a decorative laminate plate 10 according to FIG. 2 with a rigid carrier material, for example carrier plates based on wood-based materials by means of adhesives, it is necessary to bend the decorative laminate over these edges.

FIG. 4 schematically shows how a decorative laminate 10 is continuously applied to a carrier plate 20 on two successive sides, forming a rounded bending edge 108 .

Since the decorative laminate sheets in HPL quality can only be re-deformed to a limited extent, only outer radii AR in the region of the bending edges 108 of at least ten times the thickness of the decorative laminate sheets used can be realized for decorative laminate sheets in thicknesses from 0.6 to 1.2 mm, ie here 6 mm to 12 mm for laminated panels with thicknesses of 0.6 mm to 1.3 mm.

According to the invention, it is possible, by designing the laminated sheet with a concave recess, as explained in FIG. 1 below, which have thicknesses between 0.6 to 1.3 mm, in principle with a rounded bending edge 108 , as shown in FIG. 4 to deform with an outer radius AR of only 3 mm +/- 10% tolerance, without the surface quality and the quality of the laminate being impaired.

As can be seen in FIG. 1, the decorative laminate plate 10 according to FIG. 2 is provided on its underside, ie on the side opposite the decorative layer 102 , with a concave recess 104 , viewed in cross section, which extends in the longitudinal extent of the later bending edge, ie the Both outer edges 106 , 107 of the concave recess 104 run parallel to one another and parallel to the later bending edge.

The thickness D of the laminate 10 is between 0.6 to 1.3 mm. The concave recess 104 is formed symmetrically between the two outer edges 106 , 107 and leaves at its deepest point, ie in the middle, a residual thickness DR of the laminate 10 of 0.3 mm. This remaining thickness of 0.3 mm is to be maintained with a high manufacturing tolerance, so that the decorative layer 102 is completely preserved and a residual layer of the base layer 103 is also present in this area. The width of the concave recess 104 BR should always be 7 mm.

Provided that the remaining thickness DR of the laminated sheet 10 with 0.3 mm and the width BR of the concave recess 104 with 7 mm, manufacturing tolerances are allowed, it is possible to produce bending edges with roundings of the laminated sheets, in which the outer radius is approx. 3 mm is +/- a manufacturing tolerance of 0.3 mm.

The decorative laminated sheet 10 has as many recesses 104 with a concave cross-section as it should have bending edges for connection to a carrier material. The recesses 104 with a concave cross section are produced by subsequently milling out the decorative laminated panels 10 on their underside in the base layer 103 according to FIG. 1.

To produce a composite panel 1 according to FIG. 4, the carrier panel 20 according to FIG. 3 is first formed, for example, from a medium-density fiberboard or a particle board at the transition from the surface side 202 to the narrow side 203 , where the round corner is to be formed, with a rounded edge 201 . This rounded edge 201 has a radius R that is smaller by the thickness DR than the desired outer radius AR of the bending edge of the laminate, ie with a desired outer radius of 3.0 mm and residual thickness DR of 0.3 mm, the radius R is Carrier plate 20 2.7 mm.

In FIG. 5 is illustrated schematically how the laminated sheet 10 is applied by means of the pressure applied to both contact surfaces with adhesive 3, the carrier plate 20 already on the larger contact surface 202 and is firmly bonded. The edge strip 109 of the laminated sheet 10 , which serves to clad the narrow side 203 of the support plate 20 , projects beyond the narrow side, including the concave recess 104 forming the bending edge. After preheating the edge strip 109, in particular in the region of the recess 104, for example by means of IR emitters, the edge strip 109 is bent over the corner 201 of the carrier plate 20 in the direction of arrow P by means of rollers (not shown) and pressed onto the narrow side 203 to form the rounded bending edge with the desired small outer radius AR of about 3 mm. In this way, the composite panel 1 with a rounded corner with a rounded bending edge 108 with a very small outer radius AR is formed, as shown schematically in FIG. 4.

For the formation of panels, as shown in FIG. 6, a carrier plate 20 is provided, which is connected on three sides with the decorative laminate continuously adherent by means of the adhesive 3 . To form two rounded bending edges with a small outer radius of approximately 3 mm, the decorative laminate plate 10 is provided on the underside with two mutually parallel recesses 104 at a distance from the edges of the carrier plate 20 . The production then takes place as described in FIG. 5, the decorative laminate being first applied to the large, flat surface of the carrier plate 20 and then the narrow sides are then clad by bending the edge strips of the decorative laminated panel to form the correspondingly rounded bending edges.

In FIG. 7 it can be seen how when lining up composite panels 1 , for example panels, to form a continuous surface in the area of the butt joints of the composite panels 1, only very small visible joints 2 are formed due to the bending edges 108 with a very small outer radius.

The invention enables while maintaining the Surface quality, decorative laminate with HPL quality with small outer radii of much smaller than 5 mm, namely at least up to 3 mm.

Claims (10)

1. Decorative laminated sheet ( 10 ) with a base layer and a decorative layer that can be re-deformed, characterized by a concave recess ( 104 ) on the underside of the laminated sheet in the area of the base layer ( 103 ) along a bending edge to be formed. 2. Decorative laminated sheet according to claim 1, characterized in that for forming a bending edge ( 108 ) with an outer radius (AR) of 3 mm with a tolerance of +/- 10% regardless of the thickness of the laminated sheet ( 10 ) in the middle of concave recess ( 104 ) a residual thickness (DR) of 0.3 mm is provided and the distance between the outer edges ( 106 , 107 ) of the concave recess ( 104 ) is 7 mm +/- a tolerance of 3%. 3. Decorative laminate according to claim 1 or 2, characterized in that the concave recess ( 104 ) is formed symmetrically to its longitudinal extent in the laminate ( 10 ). 4. Decorative laminate according to one of claims 1 to 3, characterized in that high-pressure laminates (HPL) with a total thickness of 0.6 to 1.3 mm are provided as laminate ( 10 ). 5. Decorative laminate according to one of claims 1 to 4, characterized in that the laminate ( 10 ) with a carrier plate ( 20 ) by means of an adhesive ( 3 ) with formation of a rounded corner along the area of the concave recess ( 104 ) associated with the bending edge connected is. 6. A method for producing a composite panel from a decorative laminate according to one of claims 1 to 5 and a rigid carrier plate by means of an adhesive, wherein on the carrier plate on at least two sides abutting over a rounded corner with a small outer radius, a continuous laminate plate by means of the adhesive is applied to form a bending edge with an outer diameter of less than 10 mm, characterized in that

• a) a concave recess ( 104 ), viewed in cross section, is milled on the underside of the laminate ( 10 ) in a direction forming the later bending edge within the region of the base layer ( 103 ),
• b) the edge corresponding to the bending edge is rounded off on the carrier plate ( 20 ),
• c) and the surfaces of the laminate and the carrier plate ( 20 ) to be connected to one another are coated with the adhesive, provided that they have not been previously equipped with the adhesive,
• d) then the laminate ( 10 ) is applied to the larger contact surface ( 202 ) of the carrier plate ( 20 ) and the edge strip ( 109 ) of the laminate ( 10 ) including the concave recess ( 104 ) projecting beyond this contact surface is heated so far that the edge strip ( 109 ) is deformed using pressure until it abuts the support plate ( 20 ) to form a rounded corner ( 108 ).

7. The method according to claim 6, characterized in that for forming a bending edge with an outer radius (AR) of 3 mm with a tolerance of +/- 10% regardless of the thickness of the laminate ( 10 ), a concave recess ( 104 ) with a Residual thickness (DR) of 0.3 mm in the middle of the concave recess from the laminate ( 10 ) and with a distance between the outer edges ( 106 , 107 ) of the concave recess remaining distance of 7 mm +/- 3% tolerance is milled and a rounded corner is formed on the carrier plate ( 20 ) with an outer radius that is smaller by the remaining thickness (DR). 8. The method according to any one of claims 6 or 7, characterized in that as laminated sheets High pressure laminates (HPL) with a total thickness of 0.6 up to 1.3 mm can be used. 9. The method according to any one of claims 6 to 8, characterized in that carrier plates ( 20 ) are used based on wood materials. 10. The method according to any one of claims 6 to 9, characterized in that for each bending edge of a decorative laminate a corresponding recess with a concave cross-section on the underside of the laminate in the base layer ( 103 ) is made by milling.