EP2189298B1 - Verfahren zur Herstellung dekorativer Platten oder Laminate mit Geweben - Google Patents

Verfahren zur Herstellung dekorativer Platten oder Laminate mit Geweben Download PDF

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Publication number
EP2189298B1
EP2189298B1 EP08425752A EP08425752A EP2189298B1 EP 2189298 B1 EP2189298 B1 EP 2189298B1 EP 08425752 A EP08425752 A EP 08425752A EP 08425752 A EP08425752 A EP 08425752A EP 2189298 B1 EP2189298 B1 EP 2189298B1
Authority
EP
European Patent Office
Prior art keywords
decorative
fabric layer
fabric
overlay
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.)
Active
Application number
EP08425752A
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English (en)
French (fr)
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EP2189298A1 (de
EP2189298B8 (de
Inventor
Alessandro Carrara
Stefano Monti
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.)
Cleaf SpA
Original Assignee
Cleaf SpA
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 Cleaf SpA filed Critical Cleaf SpA
Priority to EP08425752A priority Critical patent/EP2189298B8/de
Priority to ES08425752T priority patent/ES2401718T3/es
Priority to PT84257526T priority patent/PT2189298E/pt
Publication of EP2189298A1 publication Critical patent/EP2189298A1/de
Publication of EP2189298B1 publication Critical patent/EP2189298B1/de
Application granted granted Critical
Publication of EP2189298B8 publication Critical patent/EP2189298B8/de
Priority to CY20131100191T priority patent/CY1114696T1/el
Active legal-status Critical Current
Anticipated expiration legal-status Critical

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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
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00—Coverings or linings, e.g. for walls or ceilings
    • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements

Definitions

  • the present invention relates to a method of producing a decorative panel or laminate, comprising the steps of:
  • Document EP-A-327 095 discloses a method for preparating a thermosetting resin decorative material wherein a resin-impregnated layer constitutes the surface of the decorative panel.
  • a first known technique provides for a printing process.
  • the surface of the panel is printed directly by digital or silk-screen technology and then varnished.
  • the paper is first of all decorated by digital or rotary printing and is then saturated with thermosetting resins (mainly ureic and melamine resins) and pressed to produce faced panels or laminates.
  • thermosetting resins mainly ureic and melamine resins
  • the printed surfaces are simply imitations of the fabric; the synthetic surface does not have the same visual and tactile characteristics as the natural product.
  • Another known method provides for an interlamination process which constitutes the known technique that is closest to the invention.
  • this process which is known in the field of high-pressure laminates (HPL)
  • real fabric is interposed between two melamine overlays and pressed.
  • HPL high-pressure laminates
  • the advantage of the process is the production of a realistic decorative effect.
  • even these products do not have the feel of fabric since the outer surface is synthetic, that is, the melamine resin protecting the HPL laminate.
  • the present invention proposes a method of producing rigid surfaces which enables surfaces to be obtained with a rich aesthetic appearance, a high degree of decorative flexibility and good cleanability and surface strength.
  • the subject of the invention is therefore a method of the type defined above in which:
  • the method of the invention produces rigid, fabric-covered panels or laminates with which components of any shape and thickness can be made for a wide range of uses in furnishing.
  • the fabrics constitute the surface layer and therefore retain the aesthetic and tactile characteristics of the starting fabric.
  • a method of producing a decorative panel or laminate according to the invention is now described in general with reference to Figure 1 .
  • the panel or laminate is generally indicated 1 in Figure 1 .
  • the production method comprises, in conventional manner, a step of piling up layers of material and a step of applying pressure and heat to the pile of layers thus obtained in order to bond the layers of material to one another intimately.
  • the layers of material of the pile comprise a substrate 2 of a material conventionally used in the field.
  • the substrate may be constituted, for example, by a substrate panel, generally of medium density fibre (MDF) or chipboard, by a bundle of sheets of Kraft paper impregnated with thermosetting resin, by parchment paper, or by another substrate film, or even by a combination thereof.
  • MDF medium density fibre
  • thermosetting resin thermosetting resin
  • the pile of layers further comprises one or more paper sheets impregnated with thermosetting resin.
  • These paper sheets comprise a decorative paper sheet 3 and, optionally, an overlay 4 combined with the decorative sheet 3.
  • the decorative sheet 3 may be, conventionally, coloured paper or colour-printed paper with designs, etc.
  • “Overlay” means, conventionally, a thin paper sheet which is impregnated with thermosetting resin and which can be combined with a decorative sheet with a protection or finishing function.
  • the overlay is substantially transparent or is formed so as to become transparent after the pressure and heat treatment so as to allow the decorative effect of the underlying decorative sheet 3 to be seen.
  • the pile of layers comprises a fabric layer 5 suitable for producing the decorative effect of the panel or laminate.
  • the fabric layer 5 and the decorative sheet 3 may optionally be selected so as to cooperate to produce a decorative effect combining the decorative effect provided by each.
  • the term "fabric” means a flexible layer formed by one or more arrangements of threads which intersect and are interwoven in predetermined directions and at predetermined angles.
  • all printed and non-printed fabrics both of natural fibres (jute, cotton, linen, silk, etc.) and of synthetic fibres (polyesters, nylon, lycra, etc.), and also metal mesh fabrics or mixed metal/fibre fabrics (aluminium, stainless steel, copper, silk/steel, etc.) are suitable for the method according to the invention.
  • Fabrics which have a fairly large porosity or a fairly loose weave such as to permit partial saturation and incorporation of the fabric by the resin are preferable for the purposes of the invention. In any case, it is essential that the penetration of the resins be such as not to immerse the fabric layer in the resin completely but to leave the outer surface of the fabric layer 5 exposed.
  • the pile of layers thus obtained is subjected to a step of applying pressure and heat with the purpose of bonding the paper sheet/s, substrate and fabric layer to one another intimately.
  • This step may take place conventionally in a static, single-compartment or multi-compartment press or in a continuous press.
  • the fabric layer 5 is intended to form a surface layer of the decorative panel or laminate.
  • the fabric layer is not covered with further layers that are intended permanently to form an integral part of the panel or laminate.
  • the fabric layer 5 may be covered by a release film to protect the pressure plates.
  • thermosetting resin of the decorative sheet 3 and/or of the overlay 4 is prepared in a manner such that, during the application of pressure and heat, the resin penetrates through and incorporates the fabric layer 5. With the polymerization brought about by the pressure and temperature cycle, the resin that has penetrated the fabric cross-links, irreversibly locking the fibres or threads thereof.
  • the reactivity and fluidity of the resin should therefore be such as to enable the resin to penetrate into the fabric and to cross-link, avoiding the formation of aesthetic defects.
  • a melamine resin which is modified to afford the required reactivity and fluidity may be used for the decorative sheet (in this case, the overlay may even be absent).
  • the layers indicated by reference numerals 2 to 5 are of the type described above.
  • the substrate panel 2 is generally a medium-density fibre (MDF) or chipboard panel.
  • the phenolic barriers 6 associated with the substrate panel 2 are advantageously constituted by sheets of paper impregnated with phenolic resin and have the function of permitting any subsequent operations for the post-forming of the edge of the panel.
  • the melamine balancing layer 7 is constituted, conventionally, by one or more decorative paper sheets impregnated with melamine resin and has a balancing function to prevent excessive warping of the panel due to the polymerization shrinkage of the resins.
  • the pile of layers described above is inserted between opposed plates of the facing press.
  • the press transmits the heat to the plates by means of surfaces that are heated with diathermic oil.
  • the plates are thus heated to temperatures of between about 150 and 200°C and compress the pile of layers with pressures of between 20 and 50 kg/cm 2 .
  • the fabric 5, the melamine papers 3, 4, the barriers 6 and the balancing layer 7 are pressed onto the panel 2 with cycles, for example, of 20s - 80s duration.
  • the melamine resin of the overlay 4 is fluidized and infiltrates between the fibres/threads of the fabric and then cross-links and sets.
  • the resin of the other impregnated layers also cross-links and sets so that, upon completion of the pressure and heating cycle, the papers are welded firmly to the substrate panel and to the fabric, forming a single body.
  • the resin of the balancing layer 7 keeps the panel flat.
  • the removable protective film 8 is optionally provided to protect the plate that is in contact with the fabric 5, preventing contamination with any inks or additives contained therein.
  • the plates may also be surface structured permitting further individualization by embossing of the surface.
  • HPL high-pressure laminate
  • the melamine papers 3, 4 and the fabric 5 are pressed onto a substrate 2 which is constituted by a series of Kraft paper layers impregnated with phenolic resins.
  • the press for HPL laminates reaches higher pressures than the finish-treatment press and may even reach 100 kg/cm 2 .
  • the cycles are generally longer (about 30 minutes) and the temperatures lower (between 120°C and 140°C).
  • a laminate is obtained with a thickness that depends on the number of Kraft paper sheets used as substrate (by way of indication from a minimum of 0.6 mm to a few centimetres thickness).
  • the melamine papers 3, 4, the fabric 5 and the substrate film 2 are on reels and are combined with one another in the press at a temperature of about 140-200°C, with pressures of 20-70 kg/cm 2 and times depending on the speed of the line.
  • the laminate obtained has a thickness depending on the materials used and is generally variable from a minimum of 0.1 mm to about 1 mm.
  • the fabrics represent the surface layer and therefore retain the aesthetic and tactile characteristics of the starting fabric.
  • Teflon-treatments of the fabric may be used prior to the pressing process.
  • the fabric is thus protected from most staining substances and is easier to wash.

Landscapes

  • Laminated Bodies (AREA)

Claims (8)

  1. Verfahren zur Herstellung einer dekorativen Platte oder eines dekorativen Laminats, umfassend die folgenden Schritte:
    Aufstapeln einer Mehrzahl von Materialschichten, wobei die Materialschichten Folgendes umfassen:
    - ein Substrat (2),
    - einen oder mehrere Papierbögen, die mit hitzehärtbarem Harz imprägniert sind, wobei der eine oder die mehreren Papierbögen einen dekorativen Papierbogen (3) und gegebenenfalls eine mit dem dekorativen Papierbogen kombinierte Deckschicht (4) umfassen, und
    - eine Schicht eines Gewebes (5) aus natürlichen, synthetischen oder metallischen Fasern oder einer Kombination solcher Fasern, die geeignet ist, einen dekorativen Effekt zu erzeugen, und
    Aufbringen von Druck und Hitze auf den so erhaltenen Stapel von Schichten, um den Papierbogen/die Papierbögen, das Substrat und die Gewebeschicht eng miteinander zu verbinden,
    dadurch gekennzeichnet, dass:
    die Gewebeschicht vorgesehen ist, um eine Oberflächenschicht der dekorativen Platte oder des dekorativen Laminats zu bilden, und
    das hitzehärtbare Harz des dekorativen Bogens und/oder der Deckschicht solcherart hergestellt wird, dass das Harz während des Aufbringens von Druck und Hitze durch und in die Gewebeschicht dringt, um die Gewebeschicht nicht vollständig mit dem Harz zu durchtränken, sondern die Außenfläche der Gewebeschicht frei zu lassen.
  2. Verfahren gemäß Anspruch 1, wobei der dekorative Papierbogen und die Gewebeschicht ausgewählt werden, um zusammen einen dekorativen Effekt zu erzeugen.
  3. Verfahren gemäß Anspruch 1 oder Anspruch 2, wobei die Gewebeschicht in Kontakt mit dem dekorativen Papierbogen angeordnet wird und die Deckschicht fehlt, wobei das hitzehärtbare Harz des dekorativen Papierbogens solcherart hergestellt wird, dass das Harz während des Aufbringens von Druck und Hitze durch und in die Gewebeschicht dringt.
  4. Verfahren gemäß Anspruch 1 oder Anspruch 2, wobei die Gewebeschicht in Kontakt mit der Deckschicht angeordnet wird und die Deckschicht zwischen der Gewebeschicht und dem dekorativen Papierbogen eingefügt wird, wobei lediglich das hitzehärtbare Harz der Deckschicht solcherart hergestellt wird, dass das Harz während des Aufbringens von Druck und Hitze durch und in die Gewebeschicht dringt.
  5. Verfahren gemäß einem der vorhergehenden Ansprüche, welches für die Herstellung einer verkleideten Platte vorgesehen ist, wobei das Substrat eine steife Substratplatte umfasst.
  6. Verfahren gemäß einem der Ansprüche 1 bis 4, welches für die Herstellung eines Hochdrucklaminats vorgesehen ist, wobei das Substrat ein Bündel von Kraftpapierbögen umfasst, die mit hitzehärtbarem Harz imprägniert sind.
  7. Verfahren gemäß einem der Ansprüche 1 bis 4, welches für die kontinuierliche Produktion eines Laminats vorgesehen ist, wobei das Substrat einen oder mehrere Substratfilme umfasst.
  8. Verfahren gemäß einem der vorhergehenden Ansprüche, wobei das Fasergewebe einer Fleckenschutzbehandlung, zum Beispiel einer Teflon-Behandlung, unterzogen wurde.
EP08425752A 2008-11-25 2008-11-25 Verfahren zur Herstellung dekorativer Platten oder Laminate mit Geweben Active EP2189298B8 (de)

Priority Applications (4)

Application Number Priority Date Filing Date Title
EP08425752A EP2189298B8 (de) 2008-11-25 2008-11-25 Verfahren zur Herstellung dekorativer Platten oder Laminate mit Geweben
ES08425752T ES2401718T3 (es) 2008-11-25 2008-11-25 Un método para producir estratificados o paneles decorativos con telas
PT84257526T PT2189298E (pt) 2008-11-25 2008-11-25 Processo de produção de painéis ou laminados decorativos com tecidos
CY20131100191T CY1114696T1 (el) 2008-11-25 2013-03-01 Μια μεθοδος παραγωγης διακοσμητικων πανελ ή στρωματοποιημενων υλικων (laminates) με υφασματα

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP08425752A EP2189298B8 (de) 2008-11-25 2008-11-25 Verfahren zur Herstellung dekorativer Platten oder Laminate mit Geweben

Publications (3)

Publication Number Publication Date
EP2189298A1 EP2189298A1 (de) 2010-05-26
EP2189298B1 true EP2189298B1 (de) 2012-12-19
EP2189298B8 EP2189298B8 (de) 2013-01-23

Family

ID=40512418

Family Applications (1)

Application Number Title Priority Date Filing Date
EP08425752A Active EP2189298B8 (de) 2008-11-25 2008-11-25 Verfahren zur Herstellung dekorativer Platten oder Laminate mit Geweben

Country Status (4)

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EP (1) EP2189298B8 (de)
CY (1) CY1114696T1 (de)
ES (1) ES2401718T3 (de)
PT (1) PT2189298E (de)

Families Citing this family (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
ES2378679B2 (es) * 2010-01-15 2012-10-26 Grupo Alvic Fr Mobiliario, S.L. Procedimiento de fabricación de elementos con acabado brillante para la realización de muebles u otros objetos y producto.
EP3034320B1 (de) 2014-12-19 2017-08-09 Cleaf S.p.A. Verfahren zum herstellen von dekorativen laminaten mit duftstoff und dekorativen paneelen mit duftstoff
ITUB20154267A1 (it) * 2015-10-09 2017-04-09 Giusto Manetti Battiloro S P A Laminato plastico metallizzato e relativo metodo di produzione
CN111851886A (zh) * 2020-07-12 2020-10-30 安徽尚佰智能家居有限公司 一种新中式沙发背景墙

Family Cites Families (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE2151397A1 (de) * 1971-10-15 1973-04-26 Dynamit Nobel Ag Verfahren zur herstellung von schichtpresstoffplatten aus mit dekorboegen versehenen hartpapieren
US3948713A (en) * 1973-12-12 1976-04-06 Westinghouse Electric Corporation Process for embossing high pressure decorative laminates
DE3147989A1 (de) * 1981-12-04 1983-06-16 Hoechst Ag, 6230 Frankfurt Dekoratives, insbesondere plattenfoermiges formteil, verfahren zu seiner herstellung und seine verwendung
JPH01297176A (ja) * 1988-02-03 1989-11-30 Toppan Printing Co Ltd 転写シート及び熱硬化性樹脂化粧材の製造方法
AU2002219657B2 (en) * 2000-12-29 2004-08-19 Lg Chem, Ltd. Fire-resistant panel comprising loess and fire-resistant decorative panel using the same
SE526333C2 (sv) * 2003-12-11 2005-08-23 Pergo Europ Ab Golvsystem med en pluralitet av olika övre dekorativa ytor

Also Published As

Publication number Publication date
CY1114696T1 (el) 2016-10-05
EP2189298A1 (de) 2010-05-26
PT2189298E (pt) 2013-03-22
EP2189298B8 (de) 2013-01-23
ES2401718T3 (es) 2013-04-23

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