EP1634995B1 - Impregnate and process for the production of the same - Google Patents

Impregnate and process for the production of the same Download PDF

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Publication number
EP1634995B1
EP1634995B1 EP05019549A EP05019549A EP1634995B1 EP 1634995 B1 EP1634995 B1 EP 1634995B1 EP 05019549 A EP05019549 A EP 05019549A EP 05019549 A EP05019549 A EP 05019549A EP 1634995 B1 EP1634995 B1 EP 1634995B1
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EP
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Prior art keywords
impregnate
abrasion
mixture
particles
layer
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EP05019549A
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German (de)
French (fr)
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EP1634995B2 (en
EP1634995A1 (en
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Kronotec AG
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Kronotec AG
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Classifications

    • 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
    • B44C5/0476—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 with abrasion resistant properties
    • 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
    • D21H23/00—Processes or apparatus for adding material to the pulp or to the paper
    • D21H23/02—Processes or apparatus for adding material to the pulp or to the paper characterised by the manner in which substances are added
    • D21H23/22—Addition to the formed paper
    • D21H23/50—Spraying or projecting
    • 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
    • D21H23/00—Processes or apparatus for adding material to the pulp or to the paper
    • D21H23/02—Processes or apparatus for adding material to the pulp or to the paper characterised by the manner in which substances are added
    • D21H23/22—Addition to the formed paper
    • D21H23/52—Addition to the formed paper by contacting paper with a device carrying the material
    • D21H23/56—Rolls
    • 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
    • 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
    • D21H27/28—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 treated to obtain specific resistance properties, e.g. against wear or weather

Definitions

  • the invention relates to an impregnate consisting of a decorative paper filled with aminoplast resin and an abrasion-resistant layer of corundum particles and an aminoplast resin applied on the upper side, and a cover layer of an aminoplast resin arranged above it.
  • Decorative papers with surface weights of about 70 to 80 g / m 2 are filled with melamine resin and then pressed in combination with a separately produced overlay as a two-layer construction on a wood-based panel.
  • the corundum-filled overlay papers used are relatively expensive specialty products of the paper industry and fulfill the following functions in this setup:
  • the high abrasion resistance of the coating is based on the corundum particles embedded in the overlay paper, all machine parts that come into contact with the overlay during further processing must be protected from the destructive abrasive effect of the corundum particles
  • the high-quality chromium-plated press plates which transfer their luster and their surface structuring to the substrate in the short-cycle presses should, under the given process conditions, have at least a service life of approximately 10,000 press cycles, so that the laminate floor can be treated at a reasonable cost can be produced.
  • a lifetime of the pressing plates of about 10,000 pressing cycles is achieved in the currently used overlays in that the corundum particles are incorporated by special processing techniques in the lower layers of the backing paper facing away from the press plate side.
  • a mixture of corundum particles, melamine resin and viscosity-increasing additives is applied in the impregnating machine to the decorative paper previously filled with melamine resin.
  • the decorative paper finished with abrasion resistance is processed together with a protective overlay on the basis of a carrier paper with a basis weight of about 25 g / m 2 , which effectively protects the press plate surfaces against the attack of the abrasive corundum particles.
  • two-ply product constructions can be used to produce decorative floor coatings with standard abrasion values in the order of 1,800 to 4,000 revolutions (Taber Abraser) while restricting the impact of the press panels so that at least 10,000 press cycles can be achieved.
  • the EP 1 068 394 B1 discloses the order Kurund Anlagenr melamine resins on decorative papers in Aufdüs vide. The use of corundum in grain sizes between 60 and 160 microns Although good abrasion values are achieved with good transparency of the coating, but a protection of the press plates in the further processing is not achieved.
  • the WO 02/066265 A1 discloses a method in which a layer of abrasion-resistant particles, for example corundum, is applied in a first step to the decorative paper impregnated with an amino resin, for example a melamine resin, and fibers and / or balls are applied thereto in a second step. This ensures that the fibers and / or balls form a protective covering layer above the abrasion-resistant particles.
  • the fibers or balls are made of polyester, polyamide or glass.
  • the typical fiber length is 0.5 - 5 mm.
  • a decorative laminate and a method for producing the same in which on a substrate body, for example, a wood material, a fibrous web as a carrier web and a decorative web, which is applied and impregnated with an abrasion-resistant, resin-based mass is applied.
  • the abrasion-resistant and synthetic resin-based mass consists for example of corundum particles, melamine resin and other additives such as heteropolysaccharides, pectin, natural products or natural substances.
  • the abrasion-resistant layer containing the corundum particles is already the uppermost layer according to the teaching of this document.
  • fibrous material especially cellulose fibers
  • the use of fibrous material, especially cellulose fibers, in the amino resin blend results in a significant increase in viscosity as the fibers in the resin blend settle and form fiber balls.
  • the processing of such a fiber resin mixture is problematic because the coating machines can no longer ensure the uniform application of a fiber-resin mixture with fiber balls.
  • the object of the present invention is to provide an impregnate which combines the functions of the decor paper and a separately produced overlay in a single impregnate and which satisfies the requirements of high transparency and sufficient abrasion resistance combined with long service life of the tools used in the further processing of the impregnate Machines corresponds.
  • this object is achieved by an impregnate consisting of a decorative paper filled with aminoplast, an abrasion-resistant layer of corundum particles and an aminoplast resin applied to the top of the decor paper, and an amorphous resin covering layer disposed above it, wherein in the abrasion-resistant layer and in the aminoplast resin Cover layer cellulose particles are embedded.
  • the increase in the viscosity of the resin mixture can be prevented, since in the resin mixture no more fiberballs are formed.
  • the once set viscosity of the resin mixture is maintained over a longer period of time and ensures a uniform application of the resin mixture and thus a simplified production of an impregnate.
  • aminoplast resins melamine or urea resins are preferably used.
  • the dosage of the applied amount of resin for impregnation of decorative paper can be done by means of metering rollers or scrapers, wherein the applied amount of resin is about 60 to 100% based on the weight of the decorative paper used.
  • the applied amount of resin is about 60 to 100% based on the weight of the decorative paper used.
  • urea resin instead of the melamine resin.
  • the filled decor paper is coated without further intermediate drying with a mixture of melamine resin, corundum particles and preferably coarse-grained cellulose particles.
  • the aforesaid mixture consists of 100 parts by weight of the melamine resin, 20 to 50 parts by weight of corundum and 4 to 20 parts by weight of the cellulose particles.
  • the corundum particles have a diameter of 40 to 60 microns and the cellulose particles have a diameter of 80 to 110 microns.
  • coarse-grained microcrystalline cellulose particles can be used.
  • a silanized corundum is used.
  • the silanization can also be carried out immediately before the use of the resin mixture by adding silanizing agents in the corundum-containing resin mixture.
  • a roll applicator or a nozzle applicator can be used for the application of the corundum and cellulose particle-containing resin mixture.
  • a viscosity of preferably 120 to 140 DIN sec. is set to prevent the sedimentation of corundum particles using conventional thickening agents such as xanthan.
  • the order quantities of the roller applicator are between 40 and 80 g / m 2 (atro). If the corundum and cellulose particle-containing resin mixture is applied via a nozzle applicator, the proportion of thickening agent must be reduced to such an extent that a viscosity of 25 to 80 DIN sec. Results.
  • an intermediate drying takes place.
  • a protective coating of melamine resin and preferably fine-grained cellulose particles is applied to cover the corundum particles.
  • 5 to 20 parts by weight of cellulose particles are metered onto 100 parts by weight of melamine resin.
  • the average diameter of the cellulose particles in this case is about 10 to 25 microns.
  • the order of the covering layer by means of a grid applicator. For this purpose, the viscosity of the resin-cellulose mixture is adjusted to 15 to 25 DIN sec.
  • fine-grained microcrystalline cellulose particles instead of the fine-grained cellulose particles.
  • a balance screed of an aminoplast resin is applied to ensure a good flatness or to prevent tipping of the impregnate during further processing on the underside of the impregnate.
  • the impregnate After application of the upper-side covering layer and the lower-side balance screed, the impregnate is dried down to a residual moisture of 6 to 7% in the floating dryer.
  • the particle diameter of the corundum particles in the first layer is smaller than the particle diameter of the cellulose particles.
  • the impregnate according to the invention can be used as a single-layer decorative coating material, for example for floor panels, which allows abrasion values of 1,500 to 2,000 revolutions (Taber Abraser) and at the same time ensures a sufficient protective effect for the press plates, so that 10,000 to 20,000 press cycles can be achieved with these impregnates before noticeable wear of the press plates can be seen.
  • the abrasion resistance of floor panels is tested with the Taber Abraser.
  • a floor panel is placed under a rotating grinder.
  • the grinding device consists of two vertical grinding wheels, comparable to a chair roll coated with sandpaper.
  • two-layer film structures are replaced by single-layer structures with integrated overlay and thus significantly reduces the use of materials.
  • An additional impregnation process for a separately produced overlay is eliminated. Since the separate laying of an overlay is omitted, the time for feeding a short-cycle press can be reduced by about 30%. Due to the small layer thickness of the impregnated, the shrinkage stresses on the Plate top reduced considerably and the grammage of the Gegenzugfilmes be lowered.
  • the grammage of the impregnated decor paper is about 140 g / m 2 (atro).
  • the grammage of the corundum aminoplastic layer with cellulose particles is 30-80 m 2 (atro).
  • the grammage of the covering layer of cellulose particles is 20-40 g / m 2 (atro).
  • the balance screed of aminoplast resin has a surface weight of 20 - 40 g / m 2 (atro) (the name atro describes the weight per unit area in the dart-dry state).
  • the final weight of the impregnate is 210-300 g / m 2 (atro).
  • FIGURE shows the layer structure of the impregnate.
  • the impregnate 1 of the invention consists of a decorative paper 2, which may be printed on its surface and impregnated, for example, with a melamine resin, wherein the applied resin amount is between 60% to 100% of the weight of the decorative paper used.
  • the impregnation of decorative paper 2 can be done in a conventional impregnating.
  • the inventive, abrasion-resistant mixture of melamine resin, corundum particles 6 and coarse-grained cellulose particles 7 is applied without intermediate drying.
  • the corundum melamine layer 3 with coarse-grained cellulose particles 7 consists of 20 to 50 parts by weight of corundum 6, 4 to 20 parts by weight of coarse-grained cellulose particles 7, based on 100 parts by weight of melamine resin.
  • the mean grain size of the corundum particles 6 is 40 to 60 microns.
  • the average particle size of the cellulose particles 7 is 80 to 110 ⁇ m.
  • the solids content of the melamine resin ranges from 56 to 62%.
  • silanized corundum is used.
  • Commercially available silanized corundum types can be used or the silanization can be carried out immediately before the use of the resin mixture by adding silanizing agents into the corundum-containing resin mixture.
  • a roll applicator For application of the cure-containing melamine layer 3 with coarse-grained cellulose particles 7 on the impregnated decorative paper 2, a roll applicator can be used. To prevent the sedimentation of the corundum particles, a viscosity of the mixture of 120 to 140 DIN sec is set by the addition of thickening agents such as xanthan.
  • the thickener must be reduced to the extent that a resin viscosity of 25 to 80 DIN sec reduced.
  • the order quantities are between 40 and 80 g / m 2 based on the dry weight.
  • Corundum particles are advantageously used in an amount of 20 parts by weight, based on 100 parts by weight of melamine having an average particle size of 50 ⁇ m.
  • the coarse-grained cellulose particles are advantageously used in an amount of 10 parts by weight based on 100 parts by weight of melamine resin and an average particle size of 100 microns.
  • the film consisting of the corundum-containing melamine layer 3 and the impregnated decor paper 2, is intermediately dried.
  • the covering layer is applied from fine-grained cellulose particles 8 and melamine resin 4.
  • the mixture according to the invention consists of 10 to 20 parts by weight of fine-grained cellulose particles, based on 100 parts by weight of melamine resin.
  • the diameter of the fine-grained cellulose particles 8 is 10 to 25 microns.
  • the viscosity of the mixture of melamine resin and cellulose particles should be adjusted to 15 to 25 DIN sec.
  • a raster applicator is used.
  • a melamine balance screed 5 is applied to the underside of the decorative paper 2 to ensure a good flatness of the film sheet during further processing.
  • This melamine balance screed 5 may consist of the same recipe composition as the cover layer 4 or alternatively of pure melamine resin.
  • the impregnate 1 is heated to a residual moisture content of 6 to 7% in a floating dryer. dried.
  • the basis weight of the dry impregnate 1 ranges from 210 to 300 g / m 2 (atro).
  • the impregnate 1 according to the invention can be further processed at temperatures of 165 to 170 ° C on the impregnate 1 with pressing times of 12 to 18 sec.
  • the compression of the impregnate 1 with a wood-based panel is usually carried out in a short-cycle press.
  • the cellulose particles 7, 8 used according to the invention may advantageously also consist of microcrystalline cellulose.

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  • Laminated Bodies (AREA)
  • Application Of Or Painting With Fluid Materials (AREA)
  • Glass Compositions (AREA)
  • Paper (AREA)
  • Reinforced Plastic Materials (AREA)
  • Compositions Of Macromolecular Compounds (AREA)
  • Materials For Medical Uses (AREA)

Abstract

An impregnate (1) comprising aminoplastic resin-filled base paper (2), an abrasion-resistant layer (3) of corundum particles (6) and aminoplastic resin (APR), and a covering layer of APR (4), in which cellulose particles (7, 8) are incorporated in layer (3) and in the APR of layer (4). Independent claims are also included for (1) a method (M1) for the production of (1) by adding cellulose particles (7) to the mixture for layer (3) and coating the mixture onto the base paper (2) with a roller applicator (2) a similar method (M2) in which the mixture is applied with a nozzle applicator (3) a similar method (M3) in which cellulose particles (8) are added to the APR for layer (4) and the mixture is applied with a wire applicator .

Description

Die Erfindung betrifft ein Imprägnat, bestehend aus einem mit Aminoplastharz gefüllten Dekorpapier und einer auf der Oberseite aufgebrachten, abriebfesten Schicht aus Korundpartikeln und einem Aminoplastharz, sowie einer darüber angeordneten Abdeckschicht aus einem Aminoplastharz.The invention relates to an impregnate consisting of a decorative paper filled with aminoplast resin and an abrasion-resistant layer of corundum particles and an aminoplast resin applied on the upper side, and a cover layer of an aminoplast resin arranged above it.

Dekorpapiere mit Flächengewichten von ca. 70 bis 80 g/m2 werden mit Melaminharz gefüllt und anschließend in Kombination mit einem separat hergestellten Overlay als zweilagiger Aufbau auf eine Holzwerkstoffplatte aufgepresst. Die eingesetzten korundgefüllten Overlay-Papiere sind verhältnismäßig teure Spezialprodukte der Papierindustrie und erfüllen in diesem Aufbau folgende Funktionen:Decorative papers with surface weights of about 70 to 80 g / m 2 are filled with melamine resin and then pressed in combination with a separately produced overlay as a two-layer construction on a wood-based panel. The corundum-filled overlay papers used are relatively expensive specialty products of the paper industry and fulfill the following functions in this setup:

Overlays stellen nach erfolgter Imprägnierung und Aushärtung des duroplastischen Melaminharzes eine hochtransparente und hochabriebfeste Schutzschicht für das darunter liegende Dekor dar, welche beispielsweise einem Laminatfußboden die bekannten hochwertigen Gebrauchseigenschaften vermitteln. Da die hohe Abriebbeständigkeit der Beschichtung auf den im Overlay-Papier eingebetteten Korundpartikein beruht, müssen alle Maschinenteile, die bei der Weiterverarbeitung mit dem Overlay in Kontakt kommen, vor der zerstörenden abrasiven Wirkung der Korundpartikel geschützt werden, Insbesondere die hochwertigen, verchromten Pressbleche, die in den Kurztaktpressen bei der Oberflächenausbildung ihren Glanz und ihre O-berflächenstrukturierung auf das Substrat übertragen, sollten unter den gegebenen Verfahrensbedingungen mindestens eine Lebensdauer von ca. 10.000 Presszyklen aufweisen, damit der Laminatboden mit vertretbaren Kosten produziert werden kann.Overlays represent after impregnation and curing of the thermosetting melamine resin is a highly transparent and highly abrasion-resistant protective layer for the underlying decor, which convey the known high-quality performance properties, for example, a laminate floor. Since the high abrasion resistance of the coating is based on the corundum particles embedded in the overlay paper, all machine parts that come into contact with the overlay during further processing must be protected from the destructive abrasive effect of the corundum particles In particular, the high-quality chromium-plated press plates which transfer their luster and their surface structuring to the substrate in the short-cycle presses should, under the given process conditions, have at least a service life of approximately 10,000 press cycles, so that the laminate floor can be treated at a reasonable cost can be produced.

Eine Lebensdauer der Pressbleche von ca. 10.000 Presszyklen wird bei den derzeit eingesetzten Overlays dadurch erzielt, dass die Korundpartikel durch spezielle Verfahrenstechniken in den unteren, der Pressblechseite abgewandten Schichten des Trägerpapiers eingelagert werden.A lifetime of the pressing plates of about 10,000 pressing cycles is achieved in the currently used overlays in that the corundum particles are incorporated by special processing techniques in the lower layers of the backing paper facing away from the press plate side.

Bei einem anderen bekannten Verfahren wird eine Mischung aus Korundpartikeln, Melaminharz und viskositätserhöhenden Additiven in der Imprägniermaschine auf das zuvor mit Melaminharz gefüllte Dekorpapier aufgetragen. Bei der nachfolgenden Verpressung in der Pressenanlage wird das abriebbeständig ausgerüstete Dekorpapier zusammen mit einem Schutz-Overlay auf der Basis eines Trägerpapiers mit einem Flächengewicht von ca. 25 g/m2 verarbeitet, welches die Pressblechoberflächen wirksam vor dem Angriff der abrasiven Korundpartikel schützt.In another known method, a mixture of corundum particles, melamine resin and viscosity-increasing additives is applied in the impregnating machine to the decorative paper previously filled with melamine resin. In the subsequent pressing in the press system, the decorative paper finished with abrasion resistance is processed together with a protective overlay on the basis of a carrier paper with a basis weight of about 25 g / m 2 , which effectively protects the press plate surfaces against the attack of the abrasive corundum particles.

Mit beiden Verfahrenstechniken lassen sich mit Hilfe doppellagiger Produktaufbauten dekorative Fußbodenbeschichtungen mit marktüblichen Abriebwerten in der Größenordnung von 1.800 bis ca. 4.000 Umdrehungen (Taber-Abraser) produzieren und dabei den Angriff der Pressbleche soweit einschränken, dass mindestens 10.000 Presszyklen erreicht werden können.With both techniques, two-ply product constructions can be used to produce decorative floor coatings with standard abrasion values in the order of 1,800 to 4,000 revolutions (Taber Abraser) while restricting the impact of the press panels so that at least 10,000 press cycles can be achieved.

Aus der DE 195 08 797 ist bekannt, eine Abmischung aus Kurundpartikeln in einer Korngröße von 15 bis 50 µm und Zellulosefasern mit Melaminharz in Auftragswerken wie Drahtrakel, Reverse Rollcoater oder Rasterwalze auf das Dekorpapier aufzubringen, um dadurch das zusätzliche Overlay einzusparen. Diese Verfahrenstechnik hat sich nicht durchgesetzt, da innerhalb weniger Tage die Auftrugsaggregate der Imprägniermaschine und die Pressbleche aufgrund der unzureichenden Abdeckung der Korundpartikel angegriffen wurden.From the DE 195 08 797 It is known to apply a mixture of Kurundpartikeln in a particle size of 15 to 50 microns and cellulose fibers with melamine resin in commissioned works such as wire bar, reverse roll coater or anilox roller on the decorative paper, thereby saving the additional overlay. This process technology has not prevailed, because within a few days the order of the impregnating machine and the press plates were attacked due to the insufficient coverage of the corundum particles.

Die EP 1 068 394 B1 offenbart den Auftrag kurundhaltiger Melaminharze auf Dekorpapiere im Aufdüsverfahren. Durch den Einsatz von Korund in Korngrößen zwischen 60 und 160 µm werden zwar gute Abriebswerte bei guter Transparenz der Beschichtung erreicht, aber ein Schutz der Pressbleche bei der Weiterverarbeitung wird nicht erreicht.The EP 1 068 394 B1 discloses the order Kurundhaltiger melamine resins on decorative papers in Aufdüsverfahren. The use of corundum in grain sizes between 60 and 160 microns Although good abrasion values are achieved with good transparency of the coating, but a protection of the press plates in the further processing is not achieved.

Aus der WO 00/44576 ist ein Verfahren bekannt, bei dem Korundpartikel mit einer Größe von 125 µm auf das feuchte Melaminimprägnat aufgestreut werden. Nach Zwischentrocknung wird zur Abdeckung der Korundpartikel ein Faservlies aus 80% Melaminharz und 20% Zellulosefasern aufgebracht.From the WO 00/44576 a method is known in which corundum particles with a size of 125 microns are sprinkled on the moist melamine impregnate. After intermediate drying, a fibrous web of 80% melamine resin and 20% cellulose fibers is applied to cover the corundum particles.

Die WO 02/066265 A1 offenbart ein Verfahren, bei dem in einem ersten Schritt auf das mit einem Aminoharz, beispielsweise einem Melaminharz, getränkte Dekorpapier eine Schicht abriebfester Partikel, beispielsweise Korund, aufgetragen wird und in einem zweiten Schritt hierauf Fasern und/oder Kugeln aufgebracht werden. Dadurch wird erreicht, dass die Fasern und/oder Kugeln eine schützende Abdeckschicht oberhalb der abriebfesten Partikel ausbilden. Die Fasern oder Kugeln bestehen aus Polyester, Polyamid oder Glas. Die typische Faserlänge beträgt 0,5 - 5 mm.The WO 02/066265 A1 discloses a method in which a layer of abrasion-resistant particles, for example corundum, is applied in a first step to the decorative paper impregnated with an amino resin, for example a melamine resin, and fibers and / or balls are applied thereto in a second step. This ensures that the fibers and / or balls form a protective covering layer above the abrasion-resistant particles. The fibers or balls are made of polyester, polyamide or glass. The typical fiber length is 0.5 - 5 mm.

In der EP 0875399A2 wird ein Dekorlaminat und ein Verfahren zur Herstellung desselben beschrieben, bei dem auf einem Substratkörper z.B. einem Holzwerkstoff, eine Faserstoffbahn als Trägerbahn und eine Dekorbahn, welche mit einer abrasionsresistenten, kunstharzbasierten Masse beaufschlagt und imprägniert ist, aufgebracht wird. Die abrasionsresistente und kunstharzbasierte Masse besteht beispielsweise aus Korundpartikeln, Melaminharz und weiteren Additiven wie z.B. Heteropolysacchariden, Pektin, Naturstoffen bzw. naturidenten Stoffen. Die die Korundpartikel enthaltene abriebfeste Schicht ist nach der Lehre dieses Dokumentes bereits die oberste Schicht.In the EP 0875399A2 a decorative laminate and a method for producing the same is described, in which on a substrate body, for example, a wood material, a fibrous web as a carrier web and a decorative web, which is applied and impregnated with an abrasion-resistant, resin-based mass is applied. The abrasion-resistant and synthetic resin-based mass consists for example of corundum particles, melamine resin and other additives such as heteropolysaccharides, pectin, natural products or natural substances. The abrasion-resistant layer containing the corundum particles is already the uppermost layer according to the teaching of this document.

Die Verwendung von faserartigem Material, insbesondere Zellulosefasern, in der Aminoharzmischung führt zu einem deutlichen Anstieg der Viskosität, da sich die Fasern in der Harzmischung aneinderlagern und Faserknäuel bilden. Die Verarbeitung einer solchen Faserharzmischung ist problematisch, da die Auftragsmaschinen den gleichmäßigen Auftrag einer Faser-Harzmischung mit Faserknäueln nicht mehr gewährleisten können.The use of fibrous material, especially cellulose fibers, in the amino resin blend results in a significant increase in viscosity as the fibers in the resin blend settle and form fiber balls. The processing of such a fiber resin mixture is problematic because the coating machines can no longer ensure the uniform application of a fiber-resin mixture with fiber balls.

Aufgabe der vorliegenden Erfindung ist es, ein Imprägnat bereit zu stellen das die Funktionen des Dekorpapiers und eines separat gefertigten Overlays in einem einzigen Imprägnat vereint und das den Anforderungen nach hoher Transparenz und ausreichender Abriebbeständigkeit bei gleichzeitig hohen Standzeiten der bei der Weiterverarbeitung des lmprägnates eingesetzten Werkzeuge und Maschinen entspricht.The object of the present invention is to provide an impregnate which combines the functions of the decor paper and a separately produced overlay in a single impregnate and which satisfies the requirements of high transparency and sufficient abrasion resistance combined with long service life of the tools used in the further processing of the impregnate Machines corresponds.

Erfindungsgemäß wird diese Aufgabe durch ein imprägnat bestehend aus einem mit Aminoplast gefüllten Dekorpapier, einer auf der Oberseite des Dekorpapiers aufgebrachten abriebfesten Schicht aus Korundpartikeln und einem Aminoplastharz, sowie einer darüber angeordneten Abdeckschicht aus einem Aminoplastharz gelöst, wobei in der abriebfesten Schicht und in dem Aminoplastharz der Abdeckschicht Zellulosepartikel eingelagert sind.According to the invention, this object is achieved by an impregnate consisting of a decorative paper filled with aminoplast, an abrasion-resistant layer of corundum particles and an aminoplast resin applied to the top of the decor paper, and an amorphous resin covering layer disposed above it, wherein in the abrasion-resistant layer and in the aminoplast resin Cover layer cellulose particles are embedded.

Durch den Einsatz von Zellulosepartikeln kann der Anstieg der Viskosität der Harzmischung verhindert werden, da sich in der Harzmischung keine Faserknäuel mehr bilden. Die einmal eingestellte Viskosität der Harzmischung bleibt auch über einen längeren Zeitraum erhalten und gewährleistet einen gleichmäßigen Auftrag der Harzmischung und somit eine vereinfachte Herstellung eines Imprägnates.Through the use of cellulose particles, the increase in the viscosity of the resin mixture can be prevented, since in the resin mixture no more fiberballs are formed. The once set viscosity of the resin mixture is maintained over a longer period of time and ensures a uniform application of the resin mixture and thus a simplified production of an impregnate.

Als Aminoplastharze werden bevorzugt Melamin- oder Hamstoffharze verwendet.As aminoplast resins melamine or urea resins are preferably used.

Vorteilhafterweise kann die Dosierung der aufgetragenen Harzmenge zur Imprägnierung des Dekorpapieres mit Hilfe von Dosierwalzen oder Abstreifern erfolgen, wobei die aufgetragene Harzmenge ca. 60 bis 100% bezogen auf das Gewicht des eingesetzten Dekorpapieres beträgt. Zur Produktion heller Dekore kann anstelle des Melaminharzes auch Hamstoffharz eingesetzt werden.Advantageously, the dosage of the applied amount of resin for impregnation of decorative paper can be done by means of metering rollers or scrapers, wherein the applied amount of resin is about 60 to 100% based on the weight of the decorative paper used. For the production of light decors, it is also possible to use urea resin instead of the melamine resin.

Das gefüllte Dekorpapier wird ohne weitere Zwischentrocknung mit einer Mischung aus Melaminharz, Korundpartikeln und vorzugsweise grobkörnigen Zellulosepartikeln beschichtet. Die vorgenannte Mischung besteht aus 100 Gewichtsteilen des Melaminharzes, 20 bis 50 Gewichtsteilen Korund und 4 bis 20 Gewichtsteilen der Zellulosepartikel. Vorzugsweise weisen die Korundpartikel einen Durchmesser von 40 bis 60 µm und die Zellulosepartikel einen Durchmesser von 80 bis 110 µm auf.The filled decor paper is coated without further intermediate drying with a mixture of melamine resin, corundum particles and preferably coarse-grained cellulose particles. The aforesaid mixture consists of 100 parts by weight of the melamine resin, 20 to 50 parts by weight of corundum and 4 to 20 parts by weight of the cellulose particles. Preferably, the corundum particles have a diameter of 40 to 60 microns and the cellulose particles have a diameter of 80 to 110 microns.

In einer Ausgestaltung der Erfindung können grobkörnige mikrokristalline Zellulosepartikel eingesetzt werden.In one embodiment of the invention, coarse-grained microcrystalline cellulose particles can be used.

Zur Erreichung einer optimalen Transparenz der endgültigen Beschichtung wird ein silanisierter Korund verwendet. Nach einer Ausgestaltung der Erfindung kann die Silanisierung auch unmittelbar vor dem Einsatz der Harzmischung durch Zugabe von Silanisierungsmitteln in die korundhaltige Harzmischung erfolgen.To achieve optimum transparency of the final coating, a silanized corundum is used. According to one embodiment of the invention, the silanization can also be carried out immediately before the use of the resin mixture by adding silanizing agents in the corundum-containing resin mixture.

Für den Auftrag der korund- und zellulosepartikelhaltigen Harzmischung kann ein Walzenauftragswerk oder ein Düsenauftragswerk eingesetzt werden.For the application of the corundum and cellulose particle-containing resin mixture, a roll applicator or a nozzle applicator can be used.

Beim Einsatz eines Walzenauftragswerks wird zur Verhinderung der Sedimentation von Korundpartikeln mit Hilfe üblicher Verdickungsmittel wie zum Beispiel Xanthan eine Viskosität von vorzugsweise 120 bis 140 DIN sec. eingestellt. Die Auftragsmengen des Walzenauftragswerkes liegen zwischen 40 und 80 g/m2 (atro). Wird die korund- und zellulosepartikelhaltige Harzmischung über ein Düsenauftragswerk aufgetragen, muss der Anteil des Verdickungsmittels soweit reduziert werden, dass eine Viskosität von 25 bis 80 DIN sec. resultiert.When using a roll applicator, a viscosity of preferably 120 to 140 DIN sec. Is set to prevent the sedimentation of corundum particles using conventional thickening agents such as xanthan. The order quantities of the roller applicator are between 40 and 80 g / m 2 (atro). If the corundum and cellulose particle-containing resin mixture is applied via a nozzle applicator, the proportion of thickening agent must be reduced to such an extent that a viscosity of 25 to 80 DIN sec. Results.

Im Anschluss an die Beschichtung des gefüllten Papieres mit der Melaminharz-Korund- und der grobkörnigen Zellulosepartikelmischung erfolgt eine Zwischentrocknung. Nach Beendigung der Zwischentrocknung wird zur Abdeckung der Korundpartikel ein Schutzüberzug aus Melaminharz und vorzugsweise feinkörnigen Zellulosepartikeln aufgetragen. Vorteilhafterweise werden dabei auf 100 Gewichtsteile Melaminharz 5 bis 20 Gewichtsteile Zellulosepartikel dosiert. Der mittlere Durchmesser der Zellulosepartikel beträgt hierbei ca. 10 bis 25 µm. Der Auftrag der Abdeckschicht erfolgt mittels eines Rasterauftragswerkes. Dazu wird die Viskosität der Harz-Zellulosemischung auf 15 bis 25 DIN sec. eingestellt.Subsequent to the coating of the filled paper with the melamine resin-corundum and the coarse-grained cellulose particle mixture, an intermediate drying takes place. After completion of the intermediate drying, a protective coating of melamine resin and preferably fine-grained cellulose particles is applied to cover the corundum particles. Advantageously, 5 to 20 parts by weight of cellulose particles are metered onto 100 parts by weight of melamine resin. The average diameter of the cellulose particles in this case is about 10 to 25 microns. The order of the covering layer by means of a grid applicator. For this purpose, the viscosity of the resin-cellulose mixture is adjusted to 15 to 25 DIN sec.

In einer Ausgestaltung der Erfindung können anstelle der feinkörnigen ZellulosePartikel auch feinkörnige mikrokristalline Zellulosepartikel eingesetzt werden.In one embodiment of the invention, it is also possible to use fine-grained microcrystalline cellulose particles instead of the fine-grained cellulose particles.

Vorzugsweise wird zur Sicherstellung einer guten Planlage bzw. zur Verhinderung von Schüsselungen des imprägnates bei der Weiterverarbeitung auf der Unterseite des Imprägnates ein Balancestrich aus einem Aminoplastharz aufgebracht.Preferably, a balance screed of an aminoplast resin is applied to ensure a good flatness or to prevent tipping of the impregnate during further processing on the underside of the impregnate.

Nach Auftrag der oberseitigen Abdeckschicht und des unterseitigen Balancestriches wird das Imprägnat im Schwebetrockner auf eine Restfeuchte von 6 bis 7 % heruntergetrocknet.After application of the upper-side covering layer and the lower-side balance screed, the impregnate is dried down to a residual moisture of 6 to 7% in the floating dryer.

Vorzugsweise ist der Teilchendurchmesser der Korundpartikel in der ersten Schicht kleiner als der Partikeldurchmesser der Zellulosepartikel.Preferably, the particle diameter of the corundum particles in the first layer is smaller than the particle diameter of the cellulose particles.

Das erfindungsgemäße Imprägnat kann als einlagiger dekorativer Beschichtungswerkstoff beispielsweise für Fußbodenpaneele eingesetzt werden, der Abriebwerte von 1.500 bis 2.000 Umdrehungen (Taber-Abraser) ermöglicht und gleichzeitig eine ausreichende Schutzwirkung für die Pressbleche sicherstellt, so dass 10.000 bis zu 20.000 Presszyklen mit diesen Imprägnaten erzielt werden können, bevor ein merklicher Verschleiß der Pressbleche zu erkennen ist.The impregnate according to the invention can be used as a single-layer decorative coating material, for example for floor panels, which allows abrasion values of 1,500 to 2,000 revolutions (Taber Abraser) and at the same time ensures a sufficient protective effect for the press plates, so that 10,000 to 20,000 press cycles can be achieved with these impregnates before noticeable wear of the press plates can be seen.

Die Prüfung der Abriebsfestigkeit von Fußbodenpaneelen erfolgt mit dem sogenannten Taber-Abraser. Dazu wird ein Fußbodenpaneel unter eine rotierende Schleifeinrichtung gelegt. Die Schleifeinrichtung besteht aus zwei senkrecht stehenden Schleifscheiben, vergleichbar mit einer mit Schleifpapier beschichteten Stuhlrolle. Als Messwert dient der Mittelwert der Umdrehungszahlen, die benötigt werden, vom ersten Angriff des Druckbildes bis zum Verschwinden des Druckdekores.The abrasion resistance of floor panels is tested with the Taber Abraser. For this purpose, a floor panel is placed under a rotating grinder. The grinding device consists of two vertical grinding wheels, comparable to a chair roll coated with sandpaper. The mean value of the number of revolutions needed, from the first attack of the printed image to the disappearance of the printed decore, serves as the measured value.

Durch das erfindungsgemäße Verfahren werden zweilagige Filmaufbauten durch einlagige Aufbauten mit integriertem Overlay ersetzt und somit der Materialeinsatz erheblich reduziert. Ein zusätzlicher Imprägniervorgang für ein separat hergestelltes Overlay entfällt. Da die separate Legung eines Overlays entfällt, kann die Zeitspanne für die Beschickung einer Kurztaktpresse um ca. 30% reduziert werden. Auf Grund der geringen Schichtdicke des imprägnates können die Schrumpfspannungen an der Plattenoberseite erheblich reduziert und die Grammatur des Gegenzugfilmes abgesenkt werden.By the method according to the invention, two-layer film structures are replaced by single-layer structures with integrated overlay and thus significantly reduces the use of materials. An additional impregnation process for a separately produced overlay is eliminated. Since the separate laying of an overlay is omitted, the time for feeding a short-cycle press can be reduced by about 30%. Due to the small layer thickness of the impregnated, the shrinkage stresses on the Plate top reduced considerably and the grammage of the Gegenzugfilmes be lowered.

Die Grammatur des imprägnierten Dekorpapieres beträgt ca. 140 g/m2 (atro). Die Grammatur der korundhaltigen Aminoplastschicht mit Zellulosepartikeln beträgt 30 - 80 m2 (atro). Die Grammatur der Abdeckschicht aus Zellulosepartikeln beträgt 20 - 40 g/m2 (atro). Der Balancestrich aus Aminoplastharz weist ein Flächengewicht von 20 - 40 g/m2 (atro) auf (die Bezeichnung atro beschreibt das Flächengewicht im dartrockenen Zustand).The grammage of the impregnated decor paper is about 140 g / m 2 (atro). The grammage of the corundum aminoplastic layer with cellulose particles is 30-80 m 2 (atro). The grammage of the covering layer of cellulose particles is 20-40 g / m 2 (atro). The balance screed of aminoplast resin has a surface weight of 20 - 40 g / m 2 (atro) (the name atro describes the weight per unit area in the dart-dry state).

Das Endgewicht des lmprägnates beträgt 210 - 300 g/m2 (atro).The final weight of the impregnate is 210-300 g / m 2 (atro).

Nachfolgend wird anhand der einzigen Figur, die den Schichtenaufbau des Imprägnates zeigt, ein Ausführungsbeispiel der Erfindung näher erläutert:An exemplary embodiment of the invention will be explained in more detail below with reference to the single FIGURE, which shows the layer structure of the impregnate.

Wie aus der Figur zu ersehen ist, besteht das erfindungsgemäße Imprägnat 1 aus einem Dekorpapier 2, das an seiner Oberfläche bedruckt sein kann und beispielsweise mit einem Melaminharz imprägniert ist, wobei die aufgetragene Harzmenge zwischen 60% bis 100% des Gewichtes des eingesetzten Dekorpapieres beträgt. Die Imprägnierung des Dekorpapieres 2 kann in einem üblichen Imprägnierwerk erfolgen.As can be seen from the figure, the impregnate 1 of the invention consists of a decorative paper 2, which may be printed on its surface and impregnated, for example, with a melamine resin, wherein the applied resin amount is between 60% to 100% of the weight of the decorative paper used. The impregnation of decorative paper 2 can be done in a conventional impregnating.

Auf die Oberseite des gefüllten Dekorpapieres 2 wird ohne Zwischentrocknung das erfindungsgemäße, abriebfeste Gemisch aus Melaminharz, Korundportikeln 6 und grobkörnigen Zellulosepartikeln 7 aufgebracht.On top of the filled decorative paper 2, the inventive, abrasion-resistant mixture of melamine resin, corundum particles 6 and coarse-grained cellulose particles 7 is applied without intermediate drying.

Die korundhaltige Melaminschicht 3 mit grobkörnigen Zellulosepartikeln 7 besteht aus 20 bis 50 Gewichtsteilen Korund 6, 4 bis 20 Gewichtsteilen grobkörnigen Zellulosepartikeln 7, bezogen auf 100 Gewichtsteile Melaminharz. Die mittlere Korngröße der Korundpartikel 6 beträgt 40 bis 60 µm. Die mittlere Korngröße der Zellulosepartikel 7 beträgt 80 bis 110 µm. Der Festkörperanteil des Melaminharzes bewegt sich in einem Bereich von 56 bis 62%.The corundum melamine layer 3 with coarse-grained cellulose particles 7 consists of 20 to 50 parts by weight of corundum 6, 4 to 20 parts by weight of coarse-grained cellulose particles 7, based on 100 parts by weight of melamine resin. The mean grain size of the corundum particles 6 is 40 to 60 microns. The average particle size of the cellulose particles 7 is 80 to 110 μm. The solids content of the melamine resin ranges from 56 to 62%.

Zur Erzielung einer optimalen Transparenz der späteren Beschichtung wird ein silanisiertes Korund verwendet. Es können handelsübliche silanisierte Korundtypen verwendet werden oder die Silanisierung kann unmittelbar vor dem Einsatz der Harzmischung durch Zugabe von Silanisierungsmitteln in die korundhaltige Harzmischung erfolgen.To achieve optimum transparency of the subsequent coating, a silanized corundum is used. Commercially available silanized corundum types can be used or the silanization can be carried out immediately before the use of the resin mixture by adding silanizing agents into the corundum-containing resin mixture.

Zum Auftrag der kurundhaltigen Melaminschicht 3 mit grobkörnigen Zellulosepartikeln 7 auf das imprägnierte Dekorpapier 2 kann ein Walzenauftragswerk verwendet werden. Zur Verhinderung der Sedimentation der Korundpartikel wird durch Zugabe von Verdickungsmitteln wie zum Beispiel Xanthan eine Viskosität der Mischung von 120 bis 140 DIN sec eingestellt.For application of the cure-containing melamine layer 3 with coarse-grained cellulose particles 7 on the impregnated decorative paper 2, a roll applicator can be used. To prevent the sedimentation of the corundum particles, a viscosity of the mixture of 120 to 140 DIN sec is set by the addition of thickening agents such as xanthan.

Es ist ebenso möglich, zum Auftrag der korundhaltigen Harzmischung mit grobkörnigen Zellulosepartikeln 7 ein Düsenauftragswerk zu verwenden. In diesem Fall muss das Verdickungsmittel soweit reduziert werden, dass eine Harzviskosität von 25 bis 80 DIN sec reduziert. Die Auftragsmengen liegen zwischen 40 und 80 g/m2 bezogen auf das Trockengewicht.It is also possible to use a nozzle applicator for applying the corundum-containing resin mixture with coarse-grained cellulose particles 7. In this case, the thickener must be reduced to the extent that a resin viscosity of 25 to 80 DIN sec reduced. The order quantities are between 40 and 80 g / m 2 based on the dry weight.

Vorteilhafterweise werden Korundpartikel in einer Menge von 20 Gewichtsteilen bezogen auf 100 Gewichtsteile Melamin mit einer mittleren Korngröße von 50 µm eingesetzt. Die grobkörnigen Zellulosepartikel werden vorteilhafterweise in einer Menge von 10 Gewichtsteilen bezogen auf 100 Gewichtsteile Melaminharz und einer mittleren Korngröße von 100 µm eingesetzt.Corundum particles are advantageously used in an amount of 20 parts by weight, based on 100 parts by weight of melamine having an average particle size of 50 μm. The coarse-grained cellulose particles are advantageously used in an amount of 10 parts by weight based on 100 parts by weight of melamine resin and an average particle size of 100 microns.

Vor dem Aufbringen der Abdeckschicht wird der Film, bestehend aus der korundhaltigen Melaminschicht 3 und dem imprägnierten Dekorpapier 2, zwischengetrocknet.Before the covering layer is applied, the film, consisting of the corundum-containing melamine layer 3 and the impregnated decor paper 2, is intermediately dried.

Im nächsten Verfahrensschritt erfolgt der Auftrag der Abdeckschicht aus feinkörnigen Zellulosepartikeln 8 und Melaminharz 4. Das erfindungsgemäße Gemisch besteht aus 10 bis 20 Gewichtsteilen feinkörniger Zellulosepartikel bezogen auf 100 Gewichtsteile Melaminharz. Der Durchmesser der feinkörnigen Zellulosepartikel 8 beträgt 10 bis 25 µm. Zum Auftrag der Mischung sollte die Viskosität der Abmischung aus Melaminharz und Zellulosepartikeln auf 15 bis 25 DIN sec eingestellt werden. Zum Auftrag dieser Harzmischung wird ein Rasterauftragswerk verwendet.In the next process step, the covering layer is applied from fine-grained cellulose particles 8 and melamine resin 4. The mixture according to the invention consists of 10 to 20 parts by weight of fine-grained cellulose particles, based on 100 parts by weight of melamine resin. The diameter of the fine-grained cellulose particles 8 is 10 to 25 microns. For the application of the mixture, the viscosity of the mixture of melamine resin and cellulose particles should be adjusted to 15 to 25 DIN sec. To apply this resin mixture, a raster applicator is used.

In einem weiteren Verfahrensschritt wird auf der Unterseite des Dekorpapieres 2, zur Gewährleistung einer guten Planlage des Filmbogens bei der Weiterverarbeitung, ein Melamin-Balancestrich 5 aufgebracht Dieser Melamin-Balancestrich 5 kann aus der gleichen Rezepturzusammensetzung wie die Abdeckschicht 4 oder alternativ aus reinem Melaminharz bestehen.In a further method step, a melamine balance screed 5 is applied to the underside of the decorative paper 2 to ensure a good flatness of the film sheet during further processing. This melamine balance screed 5 may consist of the same recipe composition as the cover layer 4 or alternatively of pure melamine resin.

Im Anschluss an den unterseitigen Balancestrich wird in einem nächsten Verfahrensschritt das Imprägnat 1 in einem Schwebetrockner auf eine Restfeuchte von 6 bis 7% getrocknet. Das Flächengewicht des trockenen Imprägnates 1 bewegt sich in einem Bereich von 210 bis 300 g/m2 (atro).Subsequent to the underside balance screed, in a next process step, the impregnate 1 is heated to a residual moisture content of 6 to 7% in a floating dryer. dried. The basis weight of the dry impregnate 1 ranges from 210 to 300 g / m 2 (atro).

Durch die Einstellung einer Harzreaktivität von 220 bis 270 sec (Trübungszeiten bei 100°C) kann das erfindungsgemäße Imprägnat 1 bei Temperaturen von 165 bis 170 °C am Imprägnat 1 mit Presszeiten von 12 bis 18 sec weiterverarbeitet werden.By setting a resin reactivity of 220 to 270 sec (turbidity times at 100 ° C), the impregnate 1 according to the invention can be further processed at temperatures of 165 to 170 ° C on the impregnate 1 with pressing times of 12 to 18 sec.

Die Verpressung des Imprägnates 1 mit einer Holzwerkstoffplatte erfolgt üblicherweise in einer Kurztaktpresse.The compression of the impregnate 1 with a wood-based panel is usually carried out in a short-cycle press.

Die erfindungsgemäß eingesetzten Zellulosepartikel 7, 8 können vorteilhafterweise auch aus mikrokristalliner Zellulose bestehen.The cellulose particles 7, 8 used according to the invention may advantageously also consist of microcrystalline cellulose.

Bezugszeichenliste: List of reference numbers :

11
Imprägnatimpregnate
22
Dekorpapier imprägniertDecorative paper impregnated
33
korundhaltige Melaminschicht mit grobkörnigen Zellulosepartikelncorundum melamine layer with coarse-grained cellulose particles
44
Abdeckschicht aus feinkörnigen Zellulosepartikeln und MelaminCovering layer of fine-grained cellulose particles and melamine
55
Balancestrichbalance line
66
Korundpartikelcorundum
77
Zellulosepartikelcellulose particles
88th
Zellulosepartikelcellulose particles

Claims (24)

  1. Impregnate (1), consisting of a decorative paper (2) filled with aminoplastic resin, an abrasion-resistant layer (3) made of corundum particles (6) and an aminoplastic resin applied to the upper side of the decor paper (2), and a covering layer (4) arranged thereabove made of an aminoplastic resin, characterised in that cellulose particles (7, 8) are incorporated in the abrasion-resistant layer (3) and in the aminoplastic resin of the covering layer (4).
  2. Impregnate (1) according to claim 1, characterised in that coarse-grained cellulose particles (7) are incorporated in the abrasion-resistant layer (3).
  3. Impregnate (1) according to claim 1 or 2, characterised in that fine-grained cellulose particles (8) are incorporated in the covering layer (4).
  4. Impregnate (1) according to claim 2, characterised in that the diameter of the cellulose particles (7) in the abrasion-resistant layer (3) is 70 to 150 µm.
  5. Impregnate (1) according to claim 3, characterised in that the diameter of the cellulose particles (8) in the covering layer (4) is 10 to 25 µm.
  6. Impregnate (1) according to claim 2, characterised in that the proportion of the coarse-grained cellulose particles (7) is 4 to 20 % by weight.
  7. Impregnate (1) according to claim 3, characterised in that the proportion of fine-grained cellulose particles (8) is 5 to 20 % by weight.
  8. Impregnate (1) according to claim 1, characterised in that the cellulose particles (7, 8) consist of microcrystalline cellulose.
  9. Impregnate (1) according to any one or more of the preceding claims, characterised in that a balancing coat (5) made of an aminoplastic resin is applied to the lower side of the décor paper (2).
  10. Impregnate (1) according to any one or more of the preceding claims, characterised in that a balancing coat (5) made of a mixture of aminoplastic resin and cellulose particles is applied to the lower side of the decor paper (2).
  11. Impregnate (1) according to claim 1, characterised in that the diameter of the corundum particles (6) is 40 to 60 µm.
  12. Impregnate (1) according to claim 1, characterised in that the proportion of corundum particles (6) is 20 to 50 % by weight.
  13. Impregnate (1) according to claim 1, characterised in that the dry weight of the impregnated décor paper (2) is 140g per m2.
  14. Impregnate (1) according to claim 1, characterised in that the dry weight of the abrasion-resistant layer (3) is 30 to 80g per m2.
  15. Impregnate (1) according to claim 1, characterised in that the dry weight of the covering layer (4) is 20 to 40g per m2.
  16. Impregnate (1) according to claim 10, characterised in that the dry weight of the balancing coat (5) is 20 to 40g per m2.
  17. Impregnate (1) according to any one or more of the preceding claims, characterised in that the dry weight of the impregnate (1) is 210 to 300g per m2.
  18. Method for producing an impregnate (1) made of a decorative paper (2) filled with aminoplastic resin and an abrasion-resistant layer (3) made of a mixture of corundum particles (6) and an aminoplastic resin applied to the upper side, and a covering layer (4) arranged thereabove made of an aminoplastic resin, characterised in that cellulose particles (7) are added to the mixture of the abrasion-resistant layer (3) and the mixture is applied to the decor paper (2) by a roller application mechanism.
  19. Method according to claim 18, characterised in that the mixture of the abrasion-resistant layer (3) is adjusted to a viscosity of 120 to 140 DIN sec.
  20. Method for producing an impregnate (1) made of a decorative paper (2) filled with aminoplastic resin and an abrasion-resistant layer (3) made of a mixture of corundum particles (6) and an aminoplastic resin applied to the upper side, and a covering layer (4) arranged thereabove made of an aminoplastic resin, characterised in that cellulose particles (7) are added to the mixture of the abrasion-resistant layer - (3) and the layer is applied with a nozzle application mechanism.
  21. Method for producing an impregnate (1) according to claim 20, characterised in that the mixture of the abrasion-resistant layer (3) is adjusted to a viscosity of 25 to 80 DIN sec.
  22. Method for producing an impregnate according to claim 18 or 20, characterised in that an intermediate drying takes place after the application of the abrasion-resistant layer (3).
  23. Method for producing an impregnate (1) made of a decorative paper (2) filled with aminoplastic resin and an abrasion-resistant layer (3) made of a mixture of corundum particles (6) and an aminoplastic resin applied to the upper side, and a covering layer (4) arranged therabove made of an aminoplastic resin, characterised in that cellulose particles (8) are added to the aminoplastic resin of the covering layer (4) and the mixture is applied with a screen application mechanism.
  24. Method for producing an impregnate (1) according to claim 23, characterised in that the viscosity of the covering layer (4) is adjusted to 15 to 25 DIN sec.
EP05019549.4A 2004-09-08 2005-09-08 Impregnate and process for the production of the same Not-in-force EP1634995B2 (en)

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Applications Claiming Priority (1)

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DE102004043355A DE102004043355B4 (en) 2004-09-08 2004-09-08 impregnate

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EP1634995A1 EP1634995A1 (en) 2006-03-15
EP1634995B1 true EP1634995B1 (en) 2009-04-22
EP1634995B2 EP1634995B2 (en) 2013-08-21

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EP (1) EP1634995B2 (en)
AT (1) ATE429542T1 (en)
DE (2) DE102004043355B4 (en)
ES (1) ES2324790T5 (en)
PL (1) PL1634995T5 (en)

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WO2008061765A1 (en) * 2006-11-23 2008-05-29 S.D. Warren Company, D/B/A Method for printing directly onto boards of wood-based material
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DE102006054890A1 (en) 2006-11-20 2008-05-21 WKP Württembergische Kunststoffplatten-Werke GmbH & Co. KG Coating materials and methods for producing such coating materials
DE102007010483B4 (en) 2007-03-03 2010-09-30 Laminatepark Gmbh & Co. Kg Method for producing a panel with core and decor paper
DE102007047636A1 (en) * 2007-10-04 2009-04-09 Dakor Melamin Imprägnierungen Gmbh Process for producing an abrasion-resistant film and finishing film which can be produced by this process
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DE102008046749B4 (en) 2008-09-11 2010-10-07 Flooring Technologies Ltd. Process for the manufacture of panels from a large-format wood-based panel
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US20100221493A1 (en) * 2008-11-21 2010-09-02 Mats Hintze Use of silane-treated particles in laminates to improve clarity
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Also Published As

Publication number Publication date
ES2324790T5 (en) 2013-10-30
DE102004043355A1 (en) 2006-03-23
EP1634995B2 (en) 2013-08-21
DE502005007127D1 (en) 2009-06-04
DE102004043355B4 (en) 2006-09-21
PL1634995T5 (en) 2013-12-31
PL1634995T3 (en) 2009-08-31
ATE429542T1 (en) 2009-05-15
EP1634995A1 (en) 2006-03-15
ES2324790T3 (en) 2009-08-14

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