Classifications

• • D—TEXTILES; PAPER
  • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
  • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
  • D21H27/00—Special paper not otherwise provided for, e.g. made by multi-step processes
  • D21H27/18—Paper- or board-based structures for surface covering
  • D21H27/22—Structures being applied on the surface by special manufacturing processes, e.g. in presses
  • D21H27/26—Structures being applied on the surface by special manufacturing processes, e.g. in presses characterised by the overlay sheet or the top layers of the structures
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B44—DECORATIVE ARTS
  • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
  • B44C1/00—Processes, not specifically provided for elsewhere, for producing decorative surface effects
  • B44C1/24—Pressing or stamping ornamental designs on surfaces
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B44—DECORATIVE ARTS
  • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
  • B44C5/00—Processes for producing special ornamental bodies
  • B44C5/04—Ornamental plaques, e.g. decorative panels, decorative veneers
  • B44C5/0469—Ornamental plaques, e.g. decorative panels, decorative veneers comprising a decorative sheet and a core formed by one or more resin impregnated sheets of paper
• • D—TEXTILES; PAPER
  • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
  • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
  • D21H11/00—Pulp or paper, comprising cellulose or lignocellulose fibres of natural origin only
  • D21H11/12—Pulp from non-woody plants or crops, e.g. cotton, flax, straw, bagasse
• • D—TEXTILES; PAPER
  • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
  • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
  • D21H17/00—Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
  • D21H17/20—Macromolecular organic compounds
  • D21H17/33—Synthetic macromolecular compounds
  • D21H17/46—Synthetic macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
  • D21H17/47—Condensation polymers of aldehydes or ketones
  • D21H17/49—Condensation polymers of aldehydes or ketones with compounds containing hydrogen bound to nitrogen
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
  • Y10T156/10—Methods of surface bonding and/or assembly therefor
  • Y10T156/1002—Methods of surface bonding and/or assembly therefor with permanent bending or reshaping or surface deformation of self sustaining lamina
  • Y10T156/1028—Methods of surface bonding and/or assembly therefor with permanent bending or reshaping or surface deformation of self sustaining lamina by bending, drawing or stretch forming sheet to assume shape of configured lamina while in contact therewith

Definitions

• the invention relates to a method for producing a molded part.
• the object of the invention is to provide a method for producing a molded part with a three-dimensionally structured thermoset surface especially for furniture and components made of wood and wood-based materials.
• a decorative paper having a content of cotton linters which is at least 10% by weight and up to 100% by weight of the total fiber content in the paper is impregnated with a crosslinkable aminoplastic resin is applied to a wood-based substrate and three-dimensionally deformed under cross-linking of the resin under pressure and at elevated temperature.
• the deformation is preferably done by pressing.
• the cotton linters are spreading cotton wool of natural origin, which can be processed in a suitable manner.
• Decorative paper is conventionally made on the basis of pulp as the sole fibrous material.
• the teaching of the invention is to replace the pulp wholly or partly by cotton linters, so that the fiber content of the paper from cotton linters or a mixture of cotton linters and pulp composed.
• Pulp is almost pure cellulose.
• the blend of cotton linters and pulp is essentially a blend of cotton linters and cellulose.
• Cotton linters can be processed alone or together with pulp on a paper machine just like pure pulp. It understands itself that the decor paper used in the invention in addition to the fiber material, the usual other components of a decorative paper such. B. may contain fillers and pigments.
• Paper with a fiber content of cotton linters is known for other applications. So will the case of US 5 089 327 A Paper consisting of 8% to 16% cotton linters, soaked in a size press to saturation with an antistatic polymer. The resulting web is further processed into a multilayer high pressure laminate. The laminate is a flat part. A three-dimensional deformation does not take place.
• the US Pat. No. 4,061,823 relates to a high-pressure laminate whose core layers are made of cotton linters in paper form and contain cured phenolic resin. This laminate is also a flat part and not a three-dimensional molded part.
• the carrier and decorative paper are deformed together. This is preferably done by pressing in a stamping press (in-mold press).
• a carrier having a three-dimensional surface contour is used and the decorative paper is correspondingly shaped to this contour. This is preferably done by pressing in a membrane press.
• the fiber content is composed of cotton linters and pulp.
• the proportion of cotton linters should be 10 to 80% by weight, preferably 20 to 80% by weight of the total fiber content in the paper.
• the decor paper used in the invention has a basis weight of 40 to 200 g / m 2 . It is a voluminous paper of high absorbency, flexibility and tear resistance. The high volume and high absorbency of the paper ensure maximum resin absorption in the impregnation process.
• a decorative paper having a surface finish of a buffer system that controls the curing reaction of aminoplastic resin.
• the buffer system is applied to the decorative paper with a suitable application unit, for example a size press.
• a decorative paper is used with the bulk of a buffer system that controls the curing reaction of aminoplastic resin.
• the buffer system is entered in the mass that comes on the paper machine for processing.
• a wood fiber mat, chipboard or wood fiber board, in particular hardboard, MDF board or HDF board is used as the carrier.
• the decorative paper is applied to the carrier in one layer.
• Decorative paper with a high fiber content of cotton linters is impregnated with an aminoplastic resin. Thereafter, the paper is dried and applied to a wood-based support, such as a wood fiber mat, hardboard, medium density fiber (MDF) or high density fiber board (HDF).
• a wood-based support such as a wood fiber mat, hardboard, medium density fiber (MDF) or high density fiber board (HDF).
• MDF medium density fiber
• HDF high density fiber board
• the carrier and paper are shaped three-dimensionally in a stamping press (in-mold).
• three-dimensional deformation is meant a deformation in the length, width and height.
• the stamping press has embossing tools in the form of a male and a female mold, between which carrier and paper are pressed together.
• Male and female have a complementary surface contour, which forms as a negative on the pressing member.
• the carrier is deformed with.
• the support and the decorative paper impregnated with aminoplastic resin are subjected together to a pressure of more than 100 bar (10 MPa) and a temperature of 100 ° C to 140 ° C and pressed for a period of 1 to 5 min in one step.
• a crosslinking of the aminoplastic resin and a deformation of the entire structure takes place.
• the resin may contain suitable catalysts (hardeners).
• thermosetting (thermodur) surface layer After the pressing process, a blank having a thermosetting (thermodur) surface layer is obtained.
• the blank can be further processed in the furniture industry to a thermosetting furniture surface.
• thermosetting furniture surface according to the invention is characterized by better scratch resistance, heat resistance, adhesion to the substrate, light resistance, chemical resistance and recyclability.
• a carrier with a given three-dimensional surface contour is used.
• An example is a corresponding pre-milled MDF board called.
• the decor paper impregnated with aminoplastic resin is applied to the carrier and brought together with it into the pressure-tight press chamber of a membrane press.
• the compression chamber is vented by applying vacuum.
• carrier and decorative paper are pressed together with a pre-heated to 100 ° C to 120 ° C membrane at a pressure of 5 to 18 bar (0.5 to 1.8 MPa) in one operation.
• Of the Pressure is applied by compressed air or tempered oil.
• the duration of the pressing process is about 1 to 5 min.
• the impregnated decor paper In the membrane press alone the impregnated decor paper is deformed. It adapts to the given surface contour of the carrier and forms a thermoset surface layer thereon. In this type of press, the carrier is not deformed.
• the decor paper used withstands the stresses associated with compression molding and membrane pressing while simultaneously deforming the paper and curing the aminoplastic resin. There is no cracking. Decisive for this is that the paper has a fiber content of cotton linters of at least 10% by weight. As a result, by pressing a decorative paper, a three-dimensionally deformed thermosetting surface layer is obtained for the first time.

Landscapes

• Laminated Bodies (AREA)
• Casting Or Compression Moulding Of Plastics Or The Like (AREA)
• Crystals, And After-Treatments Of Crystals (AREA)
• Glass Compositions (AREA)
• Paper (AREA)
• Piezo-Electric Or Mechanical Vibrators, Or Delay Or Filter Circuits (AREA)
• Dry Formation Of Fiberboard And The Like (AREA)
• Reinforced Plastic Materials (AREA)
• Transition And Organic Metals Composition Catalysts For Addition Polymerization (AREA)
• Processing And Handling Of Plastics And Other Materials For Molding In General (AREA)
• Moulding By Coating Moulds (AREA)

Applications Claiming Priority (3)

Publications (2)

Family

ID=7948701

Family Applications (1)

Country Status (13)

Families Citing this family (5)

Family Cites Families (16)

• 2000
  • 2000-11-10 DE DE20019180U patent/DE20019180U1/de not_active Expired - Lifetime
• 2001
  • 2001-10-13 CN CNB018035760A patent/CN100343031C/zh not_active Expired - Fee Related
  • 2001-10-13 AU AU2002223480A patent/AU2002223480A1/en not_active Abandoned
  • 2001-10-13 PL PL355175A patent/PL196344B1/pl unknown
  • 2001-10-13 US US10/130,489 patent/US6994764B2/en not_active Expired - Lifetime
  • 2001-10-13 AT AT01993530T patent/ATE425850T1/de active
  • 2001-10-13 EP EP01993530A patent/EP1332027B1/de not_active Expired - Lifetime
  • 2001-10-13 BR BRPI0107550-0A patent/BR0107550B1/pt not_active IP Right Cessation
  • 2001-10-13 DE DE50114778T patent/DE50114778D1/de not_active Expired - Lifetime
  • 2001-10-13 CA CA2392864A patent/CA2392864C/en not_active Expired - Fee Related
  • 2001-10-13 WO PCT/DE2001/003934 patent/WO2002038345A1/de active Application Filing
  • 2001-10-13 JP JP2002540911A patent/JP3872430B2/ja not_active Expired - Fee Related
  • 2001-10-13 EA EA200300555A patent/EA004944B1/ru not_active IP Right Cessation
  • 2001-10-13 ES ES01993530T patent/ES2322553T3/es not_active Expired - Lifetime

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