EP0426793A1 - Process for making a possibly flat synthetic resin moulded block and preform for use in such a process. - Google Patents

Process for making a possibly flat synthetic resin moulded block and preform for use in such a process.

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Publication number
EP0426793A1
EP0426793A1 EP90906776A EP90906776A EP0426793A1 EP 0426793 A1 EP0426793 A1 EP 0426793A1 EP 90906776 A EP90906776 A EP 90906776A EP 90906776 A EP90906776 A EP 90906776A EP 0426793 A1 EP0426793 A1 EP 0426793A1
Authority
EP
European Patent Office
Prior art keywords
binder
compressed
layer structure
layer
resin
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP90906776A
Other languages
German (de)
French (fr)
Other versions
EP0426793B1 (en
Inventor
Fritz Haunold
Gerhard Melcher
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Isovolta AG
Original Assignee
Isovolta Osterreichische Isolierstoffwerke AG
Isovolta AG
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Isovolta Osterreichische Isolierstoffwerke AG, Isovolta AG filed Critical Isovolta Osterreichische Isolierstoffwerke AG
Publication of EP0426793A1 publication Critical patent/EP0426793A1/en
Application granted granted Critical
Publication of EP0426793B1 publication Critical patent/EP0426793B1/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B27WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27NMANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
    • B27N3/00Manufacture of substantially flat articles, e.g. boards, from particles or fibres
    • B27N3/06Making particle boards or fibreboards, with preformed covering layers, the particles or fibres being compressed with the layers to a board in one single pressing operation

Definitions

  • the invention relates to a process for the production of a synthetic resin compression molding, in which cellulose-containing fibers such as wood fibers and a binder are mixed with a condensation resin or resin mixture based on phenols and / or amino compounds and aldehyde, such as formaldehyde, and optionally together with others Materials such as top layers and / or intermediate layers are hot pressed while the binder is curing.
  • the invention further relates to a preliminary product which is suitable for being used in such a method.
  • a method of the aforementioned type is known from EP 0081147 B1.
  • This patent relates to a method for producing a decorative building board, in which an aqueous alkaline solution or dispersion of a phenol-formaldehyde resin is applied to wood fibers and the wood fibers resinated in this way are dried to a residual moisture content of 2 to 15%.
  • a fiber mat is then formed from the resin-coated and dried wood fibers, the mat is mechanically pre-compressed and then hot-pressed in one or more layers arranged one above the other to form a core layer, the decorative layer being applied to the core layer at the same time as the pressing or after this .
  • a building board is to be produced which has similar properties to the laminated boards which are produced in the customary manner Hot pressing of so-called "prepregs", which are papers impregnated with curable synthetic resins in a dry state, are produced.
  • pregs papers impregnated with curable synthetic resins in a dry state
  • the paper used is a material that is made from wood as a raw material using a relatively complex and environmentally harmful process.
  • the invention is first of all based on the object of specifying a method of the type mentioned at the beginning, in which one does not require a special process step for resin coating the wood fibers and in which, according to an advantageous variant of the invention, using readily flowable condensation resin binders, the disadvantages mentioned of the known method described above can be avoided.
  • the object underlying the invention is first in solved the method according to the invention, which is characterized in that for the continuous production of a pre-compact or a raw plate on a longitudinally moving web-shaped carrier material, a layer of a liquid binder is applied that to this fiber mass of cellulose-containing fibers such as wood fibers or bleached pulp of uniform thickness is applied in the form of a bed, a fiber cake or a mat, that if necessary a second web-shaped carrier material, to which a further layer of the liquid binder has previously been applied, is applied with the binder layer down onto the fiber mass, so that the layer structure thus formed continuously an average average density in the range between 600 and 1400 kg / m 3 , but advantageously between 800 and 1400 kg / m 3 , is compressed and heated to a higher temperature at which the viscosity of the binder is reduced so that the binder penetrates at least almost completely into the pore volume of the compressed fiber mass and is subsequently cured if necessary.
  • fibrous materials such as paper
  • the method according to the invention is characterized in that with a moisture content of the fiber mass used of at most 10% by weight, preferably at most 8% by weight, a condensation resin or resin mixture in liquid form is used as the binder for producing the binder layers which has a solid resin content of more than 80% by weight and a water content of at most 8% by weight, preferably at most 6% by weight, and the surcharge if appropriate contains substances such as color pigments.
  • the layer structure is largely heated before it is compressed by means of electromagnetic high-frequency heating.
  • the method according to the invention is characterized in that, at or after the end of the heating phase and the compression phase, the layer structure is compressed again briefly and its pore volume is reduced so much that the binder is practically uniformly distributed in the pore volume.
  • This brief compression of the layer structure can advantageously take place in a calender.
  • the method according to the invention is characterized in that the compressed layer structure passes through a cooling section after the end of the heating phase.
  • the invention further relates to the compressed layer structure produced during the process according to the invention as a preliminary product, which can advantageously be used as a pre-compact in the further process steps for the production of synthetic resin compression molded articles.
  • FIG. 1 in the figure is a schematic representation of a device for the continuous production of a pre-pressed ge shows.
  • This device essentially consists - in the production direction (see arrow) of the manufacturing process one after the other - from a rolling device 1 for a first carrier material web 2, a belt conveyor 3 with a first binder application station 4 and a device 5 for producing and feeding a wood fiber cake, a take-off device 6 for a second carrier material web 7 with a second binder application station 8, a heatable belt press 10, as well as a cooled belt press 11 and a cutting device 12.
  • the device 5 for producing and feeding a wood fiber cake consists of a wood fiber scattering device 13 with a belt conveyor 14, a compression belt 15, an isotope thickness measuring device 16 and a downstream transfer belt conveyor 17.
  • a carrier material consisting of a sodium kraft paper with a weight per unit area of 200 g / m 2 , which is impregnated with 40% resin application - a phenol-formaldehyde resin,
  • a binder consisting of a highly concentrated phenol-formaldehyde resin with a solid resin content of 86% and a water content of 5%.
  • the solid resin content is determined by reweighing after drying in a drying cabinet for 60 min at 130 ° C.
  • the water content of the resin is determined using the known Karl Fischer method.
  • the viscosity of the binder at room temperature is approximately 45,000 mPa.s.
  • the carrier material web 2 is continuously pulled off the unrolling device 1 and runs over a belt conveyor 3. From the first binder application station 4 arranged above the belt conveyor 3, the viscous phenolic resin binder 18 is used to form a binder layer 19 with a thickness of 0 , 5 mm applied.
  • a wood fiber cake 20 is continuously produced, which is placed at 21 on the binder layer 19 applied to the open belt conveyor 3.
  • 13 wood fibers in the form of a bed 22 with a bed height of 100 mm and a density of about 30 kg / m 3 are sprinkled with the aid of the scattering device.
  • This bed 22 is then compressed to a thickness of approximately 60 mm by means of the circumferential compression belt 15.
  • the basis weight of the wood fiber cake 20 thus produced is then kept constant with the aid of the isotope thickness measuring device and, for example, by controlling the spreading device.
  • the second carrier material web 7 is continuously withdrawn from the take-off device 6, which has a supply roll 23, a support plate 24 and a plurality of deflection rollers 25, and as it slides over the support plate 24 from the second binder application station 8 - in an analogous manner to the first carrier material web 2 - provided with a 0.5 mm thick binder layer 26.
  • the carrier material web 7 coated in this way is then continuously pressed onto the wood fiber cake 20, with the binder layer 26 facing downward, so that a layer structure 27 now results, which consists of the wood fiber cake 20, which is provided on both sides by carrier material webs 2 provided with binder layers 19, 26 , 7 is covered.
  • This layer structure 27 now passes through the radio frequency Heater 9, in which it is heated to a temperature of 80-140 ° C. At these temperatures, the viscosity of the binder drops to viscosity values of 100 to 300 mPa.s.
  • the layer structure 27 heated in this way is fed to the entrance of the heated belt press 10 and compressed to a density of approximately 300 kg / m 3 in its feed area.
  • the binder penetrates into the pore volume of the compressed wood fiber cake due to its reduced viscosity due to the heating, with a long residence time in the belt press 10 of 3 min Uniformity of the binder distribution over the pore volume is achieved.
  • the compressed layer structure 27 ' after leaving the belt press 10, passes through an infrared heating device and then through a calender in which the layer structure 27' which has already been compressed is briefly further strongly compacted.
  • the pore volume in the layer structure is reduced to such an extent that it is practically completely filled by the amount of binder and the binder is thus uniformly wetted on the surface of the wood fibers. This can cause any unequal moderate in the distribution of the binder within the wood fiber mass, which still exist in the layer structure 27 'when leaving the belt press 10, can be further compensated in an advantageous manner.
  • the plate-shaped high-pressure molded body which was removed from the press after cooling and cooled down has a flexural strength of 140 N / mm 2 , a tensile strength of 70 N / mm 2 and a water absorption of approximately 0.8%.
  • the method for producing a pre-compact described with reference to the figure, which is used in the production of a plate-shaped high-pressure molded body, can, with corresponding modifications, also be used directly for producing high-pressure molded bodies.
  • This is then realized, for example, by increasing the pressing pressure in the belt press 10, for example to 70 bar and the pressing temperature to 150 ° C., and extending the dwell time of the layer structure, for example to 6 minutes, so that the synthetic resin binder contained in the layer structure initially flows well and then hardens.
  • a raw plate is then removed from the belt press 10 and is cooled to 30 ° C. in the downstream cooled belt press 11. The raw plate is then cut to length and decorative lacquered or coated for further use in a known manner.
  • the molded articles produced by the process according to the invention can largely be used in the same field of application as the conventional decorative synthetic resin high-pressure laminates of greater thickness (e.g. between 3 and 15 mm thick), e.g. So for the production of self-supporting components or as weatherproof panels for outdoor use.

Abstract

In a process for making a synthetic resin moulded block from fibres containing cellulose like wood fibres and a condensation resin binder like phenolic resin, for the continuous production of a mould blank or plate, a layer (19) of the viscous binder is applied on a web-like conveyor (2), especially a paper impregnated with phenolic resin, and a fibrous mass is then applied to it in the form of a fibre cake (20). A second coated web of conveyor material (7) is then continuously laid upon the fibrous mass with the coating of binder (26) downwards, whereafter the laminated structure (27) thus obtained is heated and compressed in a heated strip press (10), whereby the binder is distributed generally uniformly on the porous volume of the laminated structure. After the compressed laminated structure (27') has cooled it is used as the preform for the production of high-pressure moulded blocks. In another embodiment of the process, the laminated structure may be directly converted into a synthetic resin moulded block by increasing the pressure, pressing temperature and the time in the strip press with the curing of the binder.

Description

Verfahren zum Herstellen eines gegebenenfalls plattenförmigen Kunstharz-Druckformkörpers sowie Vorprodukt zum Einsatz bei einem solchen Verfahren  Process for producing a possibly plate-shaped synthetic resin pressure-molded body and preliminary product for use in such a process
Technisches Gebiet Technical field
Die Erfindung betrifft ein Verfahren zur Herstellung eines Kunstharz-Druckformkörpers, bei dem zel lulosehältige Fasern wie Holzfasern und ein Bindemittel mit einem Kondensationsharz oder -harzgemisch auf Basis von Phenolen und/oder Amino- verbindungen und Aldehyd, wie Formaldehyd, gemischt und gegebenenfalls gemeinsam mit anderen Materialien wie Deck-und/ oder Zwischenschichten, unter Härtung des Bindemittels heiß verpreßt werden. Die Erfindung betrifft ferner ein Vorprodukt, das geeignet ist, bei so einem Verfahren eingesetzt zu werden. The invention relates to a process for the production of a synthetic resin compression molding, in which cellulose-containing fibers such as wood fibers and a binder are mixed with a condensation resin or resin mixture based on phenols and / or amino compounds and aldehyde, such as formaldehyde, and optionally together with others Materials such as top layers and / or intermediate layers are hot pressed while the binder is curing. The invention further relates to a preliminary product which is suitable for being used in such a method.
Stand der Technik State of the art
Ein Verfahren der vorgenannten Art ist aus der EP 0081147 B1 bekannt. Dieses Patent bezieht sich auf ein Verfahren zur Herstellung einer dekorativen Bauplatte, bei dem man auf Holzfasern eine wässrige alkalische Lösung oder Dispersion eines Phenol-Formaldehyd-Harzes aufbringt und die so beharzten Holzfasern auf eine Restfeuchte von 2 bis 15 % trocknet. Aus dem beharzten und getrockneten Holzfasern wird dann eine Faser-Matte geformt, die Matte mechanisch vorverdichtet und sie danach in einer oder mehreren übereinander angeordneten Schichten zu einer Kernschicht heiß verpreßt, wobei man die dekorative Schicht gleichzeitig mit dem Verpressen oder nacn diesem auf die Kernschicht aufbringt. A method of the aforementioned type is known from EP 0081147 B1. This patent relates to a method for producing a decorative building board, in which an aqueous alkaline solution or dispersion of a phenol-formaldehyde resin is applied to wood fibers and the wood fibers resinated in this way are dried to a residual moisture content of 2 to 15%. A fiber mat is then formed from the resin-coated and dried wood fibers, the mat is mechanically pre-compressed and then hot-pressed in one or more layers arranged one above the other to form a core layer, the decorative layer being applied to the core layer at the same time as the pressing or after this .
Mit diesem bekannten Verfahren soll eine Bauplatte erzeugt werden, die ähnliche Eigenschaften wie die in üblicher Weise hergestellten Schichtpreßstoffplatten hat, welche durch Heißverpressen von sogenannten "Prepregs", das sind mit härtbaren Kunstharzen imprägnierte Papiere in trockenem Zustand, hergestellt werden. Solche Schichtpreßstoffplatten weisen nun aber bedingt durch die bevorzugte Orientierung der ZelIstoffasern des Papiers in der Papier-Erzeugungsrichtung unter schwankenden Klimabedingungen ein in Längs- bzw. Querrichtung der eingesetzten Papiere unterschiedliches Schrumpf- und Dehnungsverhalten auf, das sich bei ihrer Anwendung nachteilig auswirken kann. Außerdem stellen die eingesetzten Papiere ein Material dar, das aus dem Rohstoff Holz durch ein relativ aufwendiges und umweltbelastendes Verfahren hergestellt wird. With this known method, a building board is to be produced which has similar properties to the laminated boards which are produced in the customary manner Hot pressing of so-called "prepregs", which are papers impregnated with curable synthetic resins in a dry state, are produced. However, due to the preferred orientation of the cellulose fibers of the paper in the paper-producing direction under fluctuating climatic conditions, such laminated boards now have different shrinkage and elongation behavior in the longitudinal and transverse directions of the papers used, which can have a disadvantageous effect when used. In addition, the paper used is a material that is made from wood as a raw material using a relatively complex and environmentally harmful process.
Bei den nach dem aus der EP 0081147 B1 bekannten Verfahren hergestellten Kunstharz-Druckformkörpern wird die genannte Anisotropie im Dehnungs- und Schrumpfverhalten vermieden und man kommt außerdem, da hier zu einem großen Teil statt Papieren direkt Holzfasern eingesetzt werden, global betrachtet mit einem geringeren Verfahrensaufwand als bei der üblichen Schichtpreßstoffplattenherstellung aus. Das Trocknen der beharzten Holzfasern bleibt aber weiter als aufwendiger und gegebenenfalls umweltbelastender Verfahrensschritt bestehen. In the case of the synthetic resin pressure-molded articles produced by the process known from EP 0081147 B1, the anisotropy mentioned in the expansion and shrinkage behavior is avoided and, since wood fibers are used to a large extent instead of paper, this is considered globally with less process effort than in the usual production of laminates. However, the drying of the resin-coated wood fibers remains as a complex and possibly environmentally harmful process step.
Darstellung der Erfindung Presentation of the invention
Der Erfindung liegt nun zunächst die Aufgabe zugrunde, ein Verfahren der eingangs der Beschreibung genannten Art anzugeben, bei dem man ohne einen besonderen Verfahrensschritt zur Beharzung der Holzfasern auskommt und bei dem gemäß einer vorteilhaften Variante der Erfindung unter Einsatz gut fließfähiger Kondensationsharz-Bindemittel die genannten Nachteile des vorstehend beschriebenen bekannten Verfahrens vermieden werden können. The invention is first of all based on the object of specifying a method of the type mentioned at the beginning, in which one does not require a special process step for resin coating the wood fibers and in which, according to an advantageous variant of the invention, using readily flowable condensation resin binders, the disadvantages mentioned of the known method described above can be avoided.
Die der Erfindung zugrunde liegende Aufgabe wird zunächst in dem erfindungsgemäßen Verfahren gelöst, das dadurch gekennzeichnet ist, daß zur kontinuierlichen Herstellung eines Vorpreßlings oder einer Rohplatte auf ein in Längsrichtung bewegtes bahnenförmiges Trägermaterial eine Schicht eines flüssigen Bindemittels aufgetragen wird, daß auf diese Fasermasse aus zellulosehältigen Fasern, wie Holzfasern oder gebleichtem Zellstoff in gleichförmiger Dicke in Form einer Schüttung, eines Faserkuchens oder einer Matte aufgebracht wird, daß gegebenenfalls ein zweites bahnenförmiges Trägermaterial, auf das zuvor eine weitere Schicht des flüssigen Bindemittels aufgetragen wurde, mit der Bindemittelschicht nach unten auf die Fasermasse aufgebracht wird, daß der so gebildete Schichtaufbau kontinuierlich auf ein durchschnittliches mittleres Raumgewicht im Bereich zwischen 600 und 1400 kg/m3, vorteilhaft aber zwischen 800 und 1400 kg/m3, komprimiert und auf eine höhere Temperatur aufgeheizt wird, bei der die Viskosität des Bindemittels verringert ist, so daß das Bindemittel zumindest nahezu vollständig in das Porenvolumen der komprimierten Fasermasse eindringt und gegebenenfalls in der Folge ausgehärtet wird. Dabei können vorteilhaft als bahnenförmige Trägermaterialien, faserige Materialien wie Papiere eingesetzt werden, die gegebenenfalls mit aushärtbaren Bindemitteln imprägniert sind und die sich beim Komprimieren der Fasermasse mit dieser bleibend verbinden. The object underlying the invention is first in solved the method according to the invention, which is characterized in that for the continuous production of a pre-compact or a raw plate on a longitudinally moving web-shaped carrier material, a layer of a liquid binder is applied that to this fiber mass of cellulose-containing fibers such as wood fibers or bleached pulp of uniform thickness is applied in the form of a bed, a fiber cake or a mat, that if necessary a second web-shaped carrier material, to which a further layer of the liquid binder has previously been applied, is applied with the binder layer down onto the fiber mass, so that the layer structure thus formed continuously an average average density in the range between 600 and 1400 kg / m 3 , but advantageously between 800 and 1400 kg / m 3 , is compressed and heated to a higher temperature at which the viscosity of the binder is reduced so that the binder penetrates at least almost completely into the pore volume of the compressed fiber mass and is subsequently cured if necessary. In this case, fibrous materials such as paper can advantageously be used as web-shaped carrier materials, which are optionally impregnated with curable binders and which permanently bond to the fiber mass when it is compressed.
Gemäß einer vorteilhaften Ausgestaltung der Erfindung ist das erfindungsgemäß Verfahren dadurch gekennzeichnet, daß bei einem Feuchtigkeitsgehalt der eingesetzten Fasermasse von maximal 10 Gew.%, vorzugsweise von maximal 8 Gew.%, als Bindemittel zur Erzeugung der Bindemittelschichten ein Kondensationsharz oder -harzgemisch in flüssiger Form verwendet wird, welches einen Festharzgehalt von mehr als 80 Gew.% und einen Wassergehalt von höchstens 8 Gew. %, vorzugsweise höchstens 6 Gew.%, aufweist, und das gegebenenfalls Zuschlag stoffe wie Farbpigmente enthält. According to an advantageous embodiment of the invention, the method according to the invention is characterized in that with a moisture content of the fiber mass used of at most 10% by weight, preferably at most 8% by weight, a condensation resin or resin mixture in liquid form is used as the binder for producing the binder layers which has a solid resin content of more than 80% by weight and a water content of at most 8% by weight, preferably at most 6% by weight, and the surcharge if appropriate contains substances such as color pigments.
Nach einer anderen vorteilhaften Ausgestaltung des erfindungsgemäßen Verfahrens erfolgt die Aufheizung des Schichtaufbaus zum größten Teil bereits vor seiner Komprimierung mittels elektromagnetischer Hochfrequenzheizung. According to another advantageous embodiment of the method according to the invention, the layer structure is largely heated before it is compressed by means of electromagnetic high-frequency heating.
In einer weiteren vorteilhaften Ausgestaltung der Erfindung ist das erfindungsgemäße Verfahren dadurch gekennzeichnet, daß zum oder nach dem Ende der Aufheizphase und der Kompressionsphase der Schichtaufbau nochmals kurzzeitig komprimiert und sein Porenvolumen dabei so stark reduziert wird, daß das Bindemittel im Porenvolumen praktisch gleichmäßig verteilt wird. Dabei kann diese kurzzeitige Komprimierung des Schichtaufbaus vorteilhaft in einem Kalander erfolgen. In a further advantageous embodiment of the invention, the method according to the invention is characterized in that, at or after the end of the heating phase and the compression phase, the layer structure is compressed again briefly and its pore volume is reduced so much that the binder is practically uniformly distributed in the pore volume. This brief compression of the layer structure can advantageously take place in a calender.
In einer letzten vorteilhaften Ausgestaltung ist das erfindungsgemäße Verfahren dadurch gekennzeichnet, daß der komprimierte Schichtaufbau nach dem Ende der Aufheizphase eine Kühlstrecke durchläuft. In a last advantageous embodiment, the method according to the invention is characterized in that the compressed layer structure passes through a cooling section after the end of the heating phase.
Die Erfindung betrifft ferner den während des erfindungsgemäßen Verfahrens hergestellten komprimierten Schichtaufbau als Vorprodukt, welches bei den weiteren Verfahrensschritten zur Herstellung von Kunstharz-Druckformkörpern vorteilhaft als Vorpreßling eingesetzt werden kann. The invention further relates to the compressed layer structure produced during the process according to the invention as a preliminary product, which can advantageously be used as a pre-compact in the further process steps for the production of synthetic resin compression molded articles.
Beschreibung einiger Wege zur Ausführung der Erfindung Description of some ways to practice the invention
anhand der Zeichnung  based on the drawing
in der Figur ist in schematischer Darstellung eine Vorrichtung zum kontinuierlichen Herstellen eines Vorpreßlings ge zeigt. Diese Vorrichtung besteht im wesentlichen - in Produktionsrichtung (siehe Pfeil) des Herstellungsverfahrens nacheinander - aus einer Abrolleinrichtung 1 für eine erste Trägermaterialbahn 2, einem Bandförderer 3 mit einer ersten Bindemittel-Auftragsstation 4 und einer Einrichtung 5 zur Erzeugung und Zuführung eines Hozfaserkuchens, einer Abzugseinrichtung 6 für eine zweite Trägermaterialbahn 7 mit einer zweiten Bindemittel-Auftragsstation 8, einer beheizbaren Bandpresse 10, sowie aus einer gekühlten Bandpresse 11 und einer Ablängeinrichtung 12. in the figure is a schematic representation of a device for the continuous production of a pre-pressed ge shows. This device essentially consists - in the production direction (see arrow) of the manufacturing process one after the other - from a rolling device 1 for a first carrier material web 2, a belt conveyor 3 with a first binder application station 4 and a device 5 for producing and feeding a wood fiber cake, a take-off device 6 for a second carrier material web 7 with a second binder application station 8, a heatable belt press 10, as well as a cooled belt press 11 and a cutting device 12.
Die Einrichtung 5 zur Erzeugung und Zuführung eines Holzfaserkuchens besteht aus einer Holzfaser-Streuvorrichtung 13 mit einem Bandförderer 14, einem Kompressionsband 15, einer Isotopen-Dickenmeßeinrichtug 16 sowie einem nachgeschalteten Übergabe-Bandförderer 17. The device 5 for producing and feeding a wood fiber cake consists of a wood fiber scattering device 13 with a belt conveyor 14, a compression belt 15, an isotope thickness measuring device 16 and a downstream transfer belt conveyor 17.
Bei einer vorteilhaften Verfahrensvariante werden als Auftragsmaterialien eingesetzt: In an advantageous process variant, the following are used as order materials:
- Holzfasern auf einen Feuchtigkeitsgehalt von 4% getrocknet, - dried wood fibers to a moisture content of 4%,
- ein Trägermaterial bestehend aus einem Natron-Kraftpapier mit einem Flächengewicht von 200g/m2, das mit 40 % Harzauftrag- eines Phenol-Formaldehydharzes imprägniert ist, a carrier material consisting of a sodium kraft paper with a weight per unit area of 200 g / m 2 , which is impregnated with 40% resin application - a phenol-formaldehyde resin,
- ein Bindemittel bestehend aus einem hochkonzentrierten Phenol-Formaldehydharz mit einem Festharzgehalt von 86% und einem Wassergehalt von 5 %. Di e Bestimmung des Festharzgehaltes erfolgt durch Rückwägung nach Trocknung im Trockenschrank während 60 min bei 130 °C. Der Wassergehalt des Harzes wird nach der bekannten Methode nach Karl Fischer bestimmt. Die Viskosität des Bindemittels bei Raumtemperatur beträgt etwa 45.000 mPa.s. Zur Durchführung des Verfahrens wird die Trägermaterialbahn 2 von der Abrolleinrichtung 1 kontinuierlich abgezogen und läuft über einen Bandförderer 3. Aus der über dem Bandförderer 3 angeordneten ersten Bindemittel-Auftragsstation 4 wird das eingesetzte dickflüssige Phenolharz-Bindemittel 18 zur Formung einer Bindemittelschicht 19 einer Dicke von 0,5 mm aufgetragen. Gleichzeitig wird kontinuierlion ein Holzfaserkuchen 20 hergestellt, der bei 21 auf die auf oen Bandförderer 3 aufgebrachte Bindemittelschicht 19 aufgelegt wird. Für die kontinuierliche Herstellung des Holzfaserkuchens 20 werden mit Hilfe der Streuvorrichtung 13 Holzfasern in Form einer Schüttung 22 mit einer Schütthöhe von 100 mm und einem Raumgewicht von etwa 30 kg/m3 aufgestreut. Diese Schüttung 22 wird anschließend mittels des umlaufenden Kompressionsbandes 15 auf eine Dicke von etwa 60 mm verdichtet. Das Flächengewicht des so hergestellten Holzfaserkuchens 20 wird anschließend mit Hilfe der Isotopen- Dickenmeßeinrichtung und z.B. durch Steuerung der Streuvorrichtung konstant gehalten. Gleichzeitig wird von der Abzugsvorrichtung 6, die eine Vorratsrolle 23, einer Supportplatte 24 und mehrere Umlenkrollen 25 aufweist, die zweite Trägermaterialbahn 7 kontinuierlich abgezogen und bei ihrem Gleiten über die Supportplatte 24 aus der zweiten Bindemittel-Auftragsstation 8 - in analoger Weise wie die erste Trägermaterialbahn 2 - mit einer 0,5 mm dicken Bindemittelschicht 26 versehen. Die so beschichtete Trägermaterialbahn 7 wird dann - mit der Bindemittelschicht 26 nach unten - kontinuierlich auf den Holzfaserkuchen 20 aufgepreßt, so daß sich nun ein Schichtaufbau 27 ergibt, der aus dem Holzfaserkuchen 20, welche an beiden Seiten von mit Bindemittelschichten 19, 26 versehenen Trägermaterialbahnen 2, 7 abgedeckt ist, besteht. - A binder consisting of a highly concentrated phenol-formaldehyde resin with a solid resin content of 86% and a water content of 5%. The solid resin content is determined by reweighing after drying in a drying cabinet for 60 min at 130 ° C. The water content of the resin is determined using the known Karl Fischer method. The viscosity of the binder at room temperature is approximately 45,000 mPa.s. To carry out the method, the carrier material web 2 is continuously pulled off the unrolling device 1 and runs over a belt conveyor 3. From the first binder application station 4 arranged above the belt conveyor 3, the viscous phenolic resin binder 18 is used to form a binder layer 19 with a thickness of 0 , 5 mm applied. At the same time, a wood fiber cake 20 is continuously produced, which is placed at 21 on the binder layer 19 applied to the open belt conveyor 3. For the continuous production of the wood fiber cake 20, 13 wood fibers in the form of a bed 22 with a bed height of 100 mm and a density of about 30 kg / m 3 are sprinkled with the aid of the scattering device. This bed 22 is then compressed to a thickness of approximately 60 mm by means of the circumferential compression belt 15. The basis weight of the wood fiber cake 20 thus produced is then kept constant with the aid of the isotope thickness measuring device and, for example, by controlling the spreading device. At the same time, the second carrier material web 7 is continuously withdrawn from the take-off device 6, which has a supply roll 23, a support plate 24 and a plurality of deflection rollers 25, and as it slides over the support plate 24 from the second binder application station 8 - in an analogous manner to the first carrier material web 2 - provided with a 0.5 mm thick binder layer 26. The carrier material web 7 coated in this way is then continuously pressed onto the wood fiber cake 20, with the binder layer 26 facing downward, so that a layer structure 27 now results, which consists of the wood fiber cake 20, which is provided on both sides by carrier material webs 2 provided with binder layers 19, 26 , 7 is covered.
Dieser Schichtaufbau 27 durchläuft nun die Hochfrequenz Heizvorrichtung 9, in der er auf eine Temperatur von 80 - 140°C erwärmt wird. Bei diesen Temperaturen sinkt die Viskosität des Bindemittels auf Viskositätswerte von 100 bis 300 mPa.s ab. Der so aufgeheizte Schichtaufbau 27 wird dem Eingang der beheizten Bandpresse 10 zugeführt und in deren Einzugsbereich auf eine Dichte von etwa 300 kg/m3 komprimiert. Beim Durchlauf durch die beheizte Bandpresse, während der die Temperatur des komprimierten Schichtaufbaus 27' gehalten wird, dringt das Bindemittel infolge seiner durch die Erwärmung verringerten Viskosität in das Porenvolumen des komprimierten Holzfaserkuchens ein, wobei bei einer Verweildauer in der Bandpresse 10 von 3 min eine hohe Gleichförmigkeit der Bindemittelverteilung über das Porenvolumen erreicht wird. Nach Verlassen der Bandpresse 10 können volatile Anteile des Bindemittels aus dem heißem komprimierten Schichtaufbau 27' ausdampfen, bevor er während des Durchlaufes durch die gekühlte Bandpresse 11 auf etwa 30°C abgekühlt und danach in der Ablängeinrichtung 12 in plattenförmige Vorpreßlinge unterteilt wird. Diese Vorpreßlinge, die gemäß dem vorliegenden Verfahrensbeispiel eine Dicke von etwa 5 - 7 mm haben, werden in üblicher Weise abgestapelt und als Vorprodukt zwischengelagert. This layer structure 27 now passes through the radio frequency Heater 9, in which it is heated to a temperature of 80-140 ° C. At these temperatures, the viscosity of the binder drops to viscosity values of 100 to 300 mPa.s. The layer structure 27 heated in this way is fed to the entrance of the heated belt press 10 and compressed to a density of approximately 300 kg / m 3 in its feed area. When passing through the heated belt press, during which the temperature of the compressed layer structure 27 'is maintained, the binder penetrates into the pore volume of the compressed wood fiber cake due to its reduced viscosity due to the heating, with a long residence time in the belt press 10 of 3 min Uniformity of the binder distribution over the pore volume is achieved. After leaving the belt press 10, volatile constituents of the binder can evaporate from the hot compressed layer structure 27 'before it is cooled to about 30 ° C. during the passage through the cooled belt press 11 and then divided into plate-shaped preforms in the cutting device 12. These pre-compacts, which according to the present process example have a thickness of approximately 5-7 mm, are stacked in the usual way and temporarily stored as a pre-product.
In Abänderung des vorstehend anhand der Figur beschriebenen Verfahrens durchläuft der komprimierte Schichtaufbau 27' nach Verlassen der Bandpresse 10 eine Infrarotheizeinrichtung und anschließend einen Kalander, in welchem der bereits komprimierte Schichtaufbau 27' kurzzeitig noch weiter stark verdichtet wird. Während dieser kurzzeitigen Verdichtung wird das Porenvolumen im Schichtaufbau so weit reduziert, daß es von der Bindemittelmenge praktisch voll ausgefüllt wird und das Bindemittel dadurch die Oberfläche der Holzfasern gleichmäßig benetzt werden. Dadurch können eventuelle Ungleich mäßigkeiten in der Verteilung des Bindemittels innerhalb der Holzfasermasse, die im Schichtaufbau 27' beim Verlassen der Bandpresse 10 noch bestehen, in vorteilhafter Weise noch weiter ausgeglichen werden. In a modification of the method described above with reference to the figure, the compressed layer structure 27 ', after leaving the belt press 10, passes through an infrared heating device and then through a calender in which the layer structure 27' which has already been compressed is briefly further strongly compacted. During this brief compression, the pore volume in the layer structure is reduced to such an extent that it is practically completely filled by the amount of binder and the binder is thus uniformly wetted on the surface of the wood fibers. This can cause any unequal moderate in the distribution of the binder within the wood fiber mass, which still exist in the layer structure 27 'when leaving the belt press 10, can be further compensated in an advantageous manner.
Zur Herstellung eines plattenförmigen Hochdruckformkörpers mit einer Dicke von 6 mm werden - zwischen zwei mit Melaminharz imprägnierten Dekorpapieren zwei solcher übereinander- gestapelten Vorpreßlinge als Kernmaterial in einer Hochdruckpresse bei 140° C und 70 bar während 20 min verpreßt, wobei die im Preßling enthaltenen Harze zunächst gut verfließen und in der Folge aushärten. In order to produce a plate-shaped high-pressure molded body with a thickness of 6 mm, two such preforms stacked one on top of the other as the core material in a high-pressure press at 140 ° C. and 70 bar are pressed between 20 between two decor papers impregnated with melamine resin, the resins contained in the compact initially being good flow and then harden.
Der nach Durchkühlung aus der Presse entnommene und abgekühlte plattenförmige Hochdruckformkörper hat eine Biegefestigkeit von 140 N/mm2, eine Zugfestigkeit von 70 N/mm2 und eine Wasseraufnahme von ca. 0,8%. The plate-shaped high-pressure molded body which was removed from the press after cooling and cooled down has a flexural strength of 140 N / mm 2 , a tensile strength of 70 N / mm 2 and a water absorption of approximately 0.8%.
Das anhand der Figur beschriebene Verfahren zur Herstellung eines Vorpreßlings, welcher bei der Erzeugung eines plattenförmigen Hochdruckformkörpers eingesetzt wird, kann mit entsprechenden Abänderungen auch direkt zur Herstellung Hochdruckformkörper verwendet werden. Dies wird dann z.B. so realisiert, daß man in der Bandpresse 10 den Preßdruck z.B. auf 70 bar und die Preßtemperatur auf 150° C erhöht sowie die Verweildauer des Schichtaufbaus z.B. auf 6 min verlängert, so daß das im Schichtaufbau enthaltene Kunstharz-Bindemittel zunächst gut verfließt und in der Folge aushärtet. Aus der Bandpresse 10 wird dann eine Rohplatte abgeführt, die in der nachgeschalteten gekühlten Bandpresse 11 auf 30°C abgekühlt wird. Die Rohplatte wird dann abgelängt und für den weiteren Gebrauch in bekannter Weise dekorativ lackiert oder beschichtet. Gewerbliche Verwertbarkeit The method for producing a pre-compact described with reference to the figure, which is used in the production of a plate-shaped high-pressure molded body, can, with corresponding modifications, also be used directly for producing high-pressure molded bodies. This is then realized, for example, by increasing the pressing pressure in the belt press 10, for example to 70 bar and the pressing temperature to 150 ° C., and extending the dwell time of the layer structure, for example to 6 minutes, so that the synthetic resin binder contained in the layer structure initially flows well and then hardens. A raw plate is then removed from the belt press 10 and is cooled to 30 ° C. in the downstream cooled belt press 11. The raw plate is then cut to length and decorative lacquered or coated for further use in a known manner. Commercial usability
Die nach dem erfindungsgemäßen Verfahren hergestellten Druckformkörper können weitgehend auf demselben Anwendungsgebiet eingesetzt werden wie die üblichen dekorativen Kunstharz- Hochdrucklaminate größerer Stärke (z.B. zwischen 3 und 15 mm dick), z.B. also zur Herstellung von selbsttragenden Bauteilen bzw. als witterungsfeste Platten zur Außenanwendung. The molded articles produced by the process according to the invention can largely be used in the same field of application as the conventional decorative synthetic resin high-pressure laminates of greater thickness (e.g. between 3 and 15 mm thick), e.g. So for the production of self-supporting components or as weatherproof panels for outdoor use.

Claims

Patentansprüche: Claims:
1. Verfahren zur Herstellung eines Kunstharz-Druckformkörpers, bei dem zellulosehältige Fasern wie Holzfasern und ein Bindemittel mit einem Kondensationsharz oder -harzgemisch auf Basis von Phenolen und/oder Aminoverbindungen und Aldehyd, wie Formaldehyd, gemischt und gegebenenfalls gemeinsam mit anderen Materialien wie Deck- und/oder Zwischenschichten, unter Härtung des Bindemittels heiß verpreßt werden, dadurch gekennzeichnet, daß zur kontinuierlichen Herstellung eines Vorpreßlings oder einer Rohplatte auf ein in Längsrichtung bewegtes bahnenförmiges Trägermaterial (2) eine Schicht des flüssigen Bindemittels aufgetragen wird, daß auf diese Bindemittelschicht (19) eine Fasermasse aus zellulosehältigen Fasern, wie Holzfasern oder gebleichtem Zellstoff, in gleichförmiger Dicke in Form einer Schüttung, eines Faserkuchens (20) oder einer Matte aufgebracht wird, daß gegebenenfalls ein zweites bahnenförmiges Trägermaterial (7), auf das zuvor eine weitere Schicht (26) des flüssigen Bindemittels aufgetragen wurde, mit der Bindemittelschicht (26) nach unten auf die Fasermasse aufgebracht wird, daß der so gebildete Schichtaufbau (27) kontinuierlich auf ein durchschnittliches mittleres Raumgewicht im Bereich zwischen 600 und 1400 kg/m3, vorteilhaft, aber zwischen 800 und 1400 kg/m3, komprimiert und auf eine höhere Temperatur aufgeheizt wird, bei der die Viskosität des Bindemittels verringert ist, so daß das Bindemittel zumindest nahezu vollständig in das Porenvolumen der komprimierten Fasermasse eindringt und gegebenenfalls in der Folge ausgehärtet wird. 1. A process for the production of a synthetic resin compression molding, in which cellulose-containing fibers such as wood fibers and a binder with a condensation resin or resin mixture based on phenols and / or amino compounds and aldehyde, such as formaldehyde, mixed and optionally together with other materials such as cover and / or intermediate layers, are hot-pressed with hardening of the binder, characterized in that for the continuous production of a pre-compact or a raw plate, a layer of the liquid binder is applied to a web-shaped carrier material (2) which is moved in the longitudinal direction, that a layer of this binder layer (19) Fiber mass made of cellulose-containing fibers, such as wood fibers or bleached cellulose, is applied in a uniform thickness in the form of a bed, a fiber cake (20) or a mat, that optionally a second web-shaped carrier material (7) on which a further layer (26) of the f Liquid binder was applied, with the binder layer (26) down onto the fiber mass, that the layer structure (27) thus formed continuously to an average average density in the range between 600 and 1400 kg / m 3 , advantageously, but between 800 and 1400 kg / m 3 , compressed and heated to a higher temperature at which the viscosity of the binder is reduced so that the binder penetrates at least almost completely into the pore volume of the compressed fiber mass and is optionally cured in the sequence.
2. Verfahren nach einem der Anspruch 1, dadurch gekennzeichnet, daß als bahnenförmige Trägermaterialien faserige Materialien wie Papiere, die gegebenenfalls mit aushärt baren Bindmitteln imprägniert sind, eingesetzt werden, und die sich beim Komprimieren der Fasermasse mit dieser bleibend verbinden. 2. The method according to any one of claim 1, characterized in that fibrous materials such as papers, which optionally also cures as web-like carrier materials baren binders are impregnated, are used, and which bind permanently with the compression of the fiber mass.
3. Verfahren nach Anspruch 1 oder 2, dadurch gekennzeichnet, daß bei einem Feuchtigkeitsgehalt der eingesetzten Fasermasse von maximal 10 Gew.%, vorzugsweise von maximal 8 Gew.%, als Bindemittel zur Erzeugung der Bindemittelschichten ein Kondensationsharz oder -harzgemisch in flüssiger Form verwendet wird, welches einen Festharzgehalt von mehr als 80 Gew.% und einen Wassergehalt von höchstens 8 Gew.%, vorzugsweise höchstens 6 Gew.%, aufweist und das gegebenenfalls Zuschlagstoffe wie Farbpigmente enthält. 3. The method according to claim 1 or 2, characterized in that at a moisture content of the fiber mass used of at most 10 wt.%, Preferably of at most 8 wt.%, A condensation resin or resin mixture in liquid form is used as the binder for producing the binder layers which has a solid resin content of more than 80% by weight and a water content of at most 8% by weight, preferably at most 6% by weight, and which optionally contains additives such as color pigments.
4. Verfahren nach einem der Ansprüche 1 bis 3, dadurch gekennzeichnet, daß die Aufheizung des Schichtaufbaus (27) zum größten Teil bereits vor seiner Komprimierung mittels elektromagnetischer Hochfrequenzheizung erfolgt. 4. The method according to any one of claims 1 to 3, characterized in that the heating of the layer structure (27) for the most part takes place before its compression by means of electromagnetic high-frequency heating.
5. Verfahren nach einem der Ansprüche 1 bis 4, dadurch gekennzeichnet, daß zumindest nach dem Ende der Aufheizphase der Schichtaufbau (27') kurzzeitig nochmals komprimiert und sein Porenvolumen dabei so stark reduziert wird, daß das Bindemittel im Porenvolumen praktisch gleichmäßig verteilt wird. 5. The method according to any one of claims 1 to 4, characterized in that at least after the end of the heating phase of the layer structure (27 ') briefly compressed again and its pore volume is reduced so much that the binder is practically evenly distributed in the pore volume.
6. Verfahren nach Anspruch 5, dadurch gekennzeichnet, daß die kurzzeitige Komprimierung des Schichtaufbaus (27') in einem Kalander erfolgt. 6. The method according to claim 5, characterized in that the short-term compression of the layer structure (27 ') takes place in a calender.
7. Verfahren nach einem der Ansprüche 1 bis 6, dadurch gekennzeichnet, daß der komprimierte Schichtaufbau (27') nach dem Ende der Komprimierungsphase eine Kühlstrecke durchläuft. 7. The method according to any one of claims 1 to 6, characterized in that the compressed layer structure (27 ') after the end of the compression phase, a cooling section goes through.
8. Vorprodukt, hergestellt während des Verfahrens nach einem der Ansprüche 1 bis 7, dadurch gekennzeichnet, daß das Vorprodukt der im Laufe des Verfahrens hergestellte komprimierte Schichtaufbau (27') ist. 8. intermediate product, produced during the method according to one of claims 1 to 7, characterized in that the intermediate product is the compressed layer structure (27 ') produced in the course of the method.
EP90906776A 1989-05-03 1990-04-27 Process for making a possibly flat synthetic resin moulded block and preform for use in such a process Expired - Lifetime EP0426793B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
AT1061/89 1989-05-03
AT1061/89A AT392758B (en) 1989-05-03 1989-05-03 METHOD FOR PRODUCING A PLANT-SHAPED PLASTIC RESIN PRINTING MOLD, AND PRE-PRODUCT FOR USE IN SUCH A METHOD

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EP0426793A1 true EP0426793A1 (en) 1991-05-15
EP0426793B1 EP0426793B1 (en) 1993-08-04

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EP (1) EP0426793B1 (en)
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AT (2) AT392758B (en)
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WO (1) WO1990013403A1 (en)

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AT397805B (en) * 1992-03-04 1994-07-25 Isovolta METHOD FOR PRODUCING A SYNTHETIC RESIN PRINTING BODY
DK0773857T3 (en) * 1994-08-01 2000-05-29 Tarkett Sommer Sa Process for making a natural or synthetic wood flooring and articles thus obtained
NL1007314C2 (en) * 1997-10-20 1999-04-21 Syntech Holdings Bv Molded element, especially a floor plate, composed of binder and ground, shredded banknotes as a filler
NL1008899C2 (en) * 1998-04-16 1999-10-19 Syntech Holdings Bv Molded element, especially a floor plate, composed of binder and ground, shredded banknotes as a filler
ATE217242T1 (en) * 1997-10-20 2002-05-15 Syntech Holdings Bv MOLDED PART, IN PARTICULAR PLATE-SHAPED MOLDED PART, WHICH CONTAINS A COMPRESSED MIXTURE OF BINDER AND FILLER, METHOD AND DEVICE FOR PRODUCING SUCH A MOLDED PART, FLOOR COVERING PANELS, SPORTS HALL PROVIDED WITH SUCH PANELS, CEILING PANELS, PROMOTIONAL GIFTS, ART OBJECTS FURNITURE AND FURNITURE
CN101758540B (en) * 2010-01-25 2013-03-20 西北农林科技大学 Reconstituted material slab layer
HUE050762T2 (en) * 2015-12-16 2021-01-28 SWISS KRONO Tec AG Method for producing an osb with a smooth surface
CN106003275B (en) * 2016-07-01 2018-01-05 鄂尔多斯市华林沙柳科技有限公司 A kind of automatic producing device and method that wooden fundamental mode material is manufactured using shrub as raw material

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FR1099184A (en) * 1953-02-19 1955-08-31 Abitibi Power & Paper Co Artificial boards
FR1283609A (en) * 1961-03-13 1962-02-02 Svenska Cellulosa Ab Process for the preparation of hard or semi-hard molded articles of wood fiber, and in particular of wood fiber panels having a resistant covering surface
DE1453390A1 (en) * 1962-05-26 1969-03-06 Holztechnik Anstalt Process for surface finishing of press plates
DE1653237B1 (en) * 1967-12-23 1971-05-13 Hombak Maschinenfab Kg Method and device for calibrating and simultaneous swelling control of wood-based panels
DE1703076A1 (en) * 1968-03-28 1972-01-05 Teutoburger Sperrholzwerk Geor Particle board, as well as processes for their manufacture

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Title
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ATA106189A (en) 1990-11-15
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AU632811B2 (en) 1993-01-14
WO1990013403A1 (en) 1990-11-15
CA2032170A1 (en) 1990-11-04
AT392758B (en) 1991-06-10
EP0426793B1 (en) 1993-08-04

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