EP2230095A1 - Decorative paper - Google Patents

Abstract

The decorative paper (100) comprises a surface lacquer and an adhesive mediator provided on an upper side (11) of the paper, where the paper is impregnated on one-side or a lower side (12) of the paper is impregnated and is provided with a coating application (15). The upper side of the paper is provided with an impregnation substance in the form of coating application. The paper is unprinted or decoratively printed. The coating application contains duroplastic resin (13) and antiblocking agent. The surface lacquer is applied on the adhesive mediator. The decorative paper (100) comprises a surface lacquer and an adhesive mediator provided on an upper side (11) of the paper, where the paper is impregnated on one-side or a lower side (12) of the paper is impregnated and is provided with a coating application (15). The upper side of the paper is provided with an impregnation substance in the form of coating application. The paper is unprinted or decoratively printed. The coating application contains duroplastic resin (13) and antiblocking agent. The surface lacquer is applied on the adhesive mediator. The one-side impregnated paper is pressable with an overlay impregnation substance. An independent claim is included for a method for producing a decorative paper.

Description

The invention relates to a decorative paper for a laminate. In addition, the invention relates to a laminate, in particular for a floor, with a decorative paper. Moreover, the invention relates to a method for producing the decorative paper.

Decorative papers of the type mentioned above are constituents of laminates, which are in the form of laminates, which are formed by pressing, gluing and / or gluing at least two layers of the same and / or different material.

The construction of laminates, which are used, for example, for the classic laminate flooring, are often designed such that the top layer contains a so-called overlay paper impregnated with synthetic resins, for example melamine resins, which contains abrasive particles embedded in the resin such as corundum particles to increase the abrasion resistance of the floor , For improved resin absorption, the overlay paper can also contain fibrous, in particular cellulosic, material.

Underneath this uppermost layer is a printed or unprinted paper impregnated with resin, usually with melamine and / or urea resins, the so-called decor paper which forms the decorative layer of the finished floor and consists of an impregnated base paper layer and a color layer and / or a pattern or decorative printing.

This decisive for the visual appearance of the floor decorative paper is applied to the top of a support plate.

As a support plate is usually a wood-based panel, z. For example, a fiberboard, such as a high-density fiberboard (HDF) or a medium-density fiberboard (MDF), or a particle board or a wood-based panel of oriented-scattered microfubers, a so-called O [riented] S [trand] B [oard].

In the manufacturing process of a laminate of the type mentioned overlay paper and decorative paper are connected by means of short pressing with serving as a carrier plate wood material board. By this pressing process, the uppermost layer, d. H. the upper layer (overlay impregnate) is completely transparent and the final product is a deconprinted image which clearly produces the desired visual effect.

An alternative product design is that the Overlayimprägnat is saved for cost reasons and instead the decorative paper is provided on the upper side with a resin layer, which is provided to protect the print layer with corundum particles.

The pressing of the carrier plate and decorative paper takes place at a laminate flooring manufacturer, which in principle has the interest to offer alternative product structures of laminates, which can be produced inexpensively and also within the framework of existing standardized compression molding.

It is therefore an object of the invention to provide a decorative paper of the type mentioned, which enables the laminate flooring manufacturer, ie the processor of decorative paper in the position to make different laminates with the same decor paper, which is characterized by a different structure, in particular of the surface texture.

This object is achieved with the features of claim 1. Advantageous developments of the invention manifest themselves in the subclaims.

The core idea of the invention is to be able to offer the processor, ie the laminate flooring manufacturer, an impregnate, which he can preferably process on his existing standardized short-cycle presses. This impregnate can advantageously be pressed onto wood-based panels as part of a normal short-cycle pressing process. The pressing can be done both with an overlay impregnate as a top layer and without this. With simultaneous compression of the decorative paper according to the invention with an overlay impregnate, the hitherto conventional laminate flooring is obtained. In a terminology used here, the side of the decor paper facing in a laminate of the carrier plate is referred to as the underside. Correspondingly, the upper side of the decorative paper is the side facing in a laminate an overlay impregnate or a lacquer layer.

Alternatively, the decorative paper according to the invention can also be pressed without Overlayimprägnat to paint the decorative paper after pressing on a wood-based panel top side with a corundum paint and / or another topcoat. An advantage of the invention is that the processor with the decorative paper impregnated on one side of the invention is given the opportunity to produce two different end products, namely the classic overlaminated impregnated melamine laminate floor panel as well as the corundum-coated panel.

Preferably, it is possible to press a non-printed, uni-colored, one-side impregnated decorative paper according to this invention, using a short-cycle press on a MDF or wood-based panel without Overlayimprägnat to this plate then on decorative printing on a printing system and painting in the context of an online coating process. This has the advantage that previously elaborate preparations with respect. The wood-based panels used in the form of necessary steps such as filling, grinding, etc. can be omitted. In addition, when using an unprinted, in particular single-colored decorative paper according to the invention, the further processor permanently has a stable color base for its subsequent decorative patterning, for example in direct printing.

According to an advantageous embodiment of the present invention, the underside of the paper is provided with an impregnate in the form of a coating order. This preferably contains as a base a plastic, preferably a thermosetting synthetic resin, preferably melamine and / or urea resin and may further be provided with acrylate resin.

Preferably, the coating application includes a thermosetting resin.

A practicable variant of the invention provides that the underside of the paper is provided with a coating order.

In order to prevent sticking when stacking from the pallet or unwinding the decorative paper according to the invention from a roll in the context of the production process, an advantageous embodiment of the invention provides that the coating application contains an antiblocking agent.

Advantageously, the decorative paper is unprinted. As a result, the processor is the opportunity to permanently have a stable color base for a subsequent Dekorausmusterung, for example, in direct print.

For this purpose, it can be provided within the scope of the invention that the unprinted (uni) decor paper provided with the resin coating on one side first to be pressed under pressure and the effect of temperature on a wood-based panel in order then to provide the non-impregnated side with a pressure. After application of the pressure, the compressed wood-based panel can be provided with a paint job.

In order to obtain a corundum-coated laminate material, provides a further advantageous embodiment of the invention that the top of the decorative paper is providable with a surface finish. For this purpose, the decor paper according to the invention can be pressed without overlay paper to paint the top of the decorative paper according to the invention with the surface finish in the form of a corundum paint and another topcoat. Again, to achieve improved adhesion with the decorative paper, it is expedient that the top of the decor paper is providable with a primer to which the surface finish can be applied.

In order to produce the decor paper according to the invention, first an impregnation of a printed or unprinted base paper layer takes place, which for reasons of cost, preferably undergoes a one-sided, back-side impregnation with a thermosetting synthetic resin, advantageously urea resin and / or melamine resin. During this impregnation, the top of the decorative paper thus produced, which can be overcoated at a later stage, is doctored off. In addition, in the context of this production, the resin application compared to the usual order quantities of 50% solid resin content, based on the dry weight of the decor paper, significantly below. The associated reduced resin weight on behalf as well as the use of urea resin result in a considerable cost saving.

In a next process step, the drying of the impregnated and printed or unprinted base paper, d. H. of decor paper.

In a step essential to the invention, the underside of the decorative paper is now coated with a layer comprising a resin, preferably a thermosetting resin. This process step is preferably realized in the context of an online application process by providing the underside of the printed or unprinted base paper layer (decorative paper) with a coating application after the pre-drying has taken place via an application device. This contains as a base thermosetting urea and / or melamine resin and is further provided with acrylate resin and an antiblocking agent. In the context of the invention, the additional addition of water is preferably dispensed with both during the impregnation which has already taken place and also during the coating of the underside. Furthermore, expediently dispensed with the addition of penetration aids such as wetting agents. It is advantageous, however, to use impregnating resins with a poor penetration behavior. The addition of the acrylate resin in the coating of the underside of the base paper layer has the advantage that a better first adhesion to the woodworking board and a poorer penetration into the decorative paper according to the invention is achieved.

Fig. 1

eine Schnittdarstellung des erfindungsgemäßen Dekorpa- piers;

Fig. 2

eine Schnittdarstellung eines Overlayimprägnatpapiers, einer Trägerplatte sowie des erfindungsgemäßen Dekorpapiers vor einer Verpressung;

Fig. 3

eine Schnittdarstellung eines Overlayimprägnatpapiers, einer Trägerplatte, sowie des erfindungsgemäßen Dekorpapiers nach der Verpressung;

Fig. 4

eine Schnittdarstellung des erfindungsgemäßen Dekorpa- piers sowie der Trägerplatte nach einer Verpressung, wobei das Overlayimprägnatpapiers durch einen Lackauftrag er- setzt ist; und

Fig. 5

eine Darstellung des Verfahrens zur Herstellung des erfin- dungsgemäßen Dekorpapiers.

The invention will be explained in more detail in embodiments with reference to the accompanying drawings. In schematic representations:

Fig. 1

a sectional view of the decorative paper according to the invention;

Fig. 2

a sectional view of a Overlayimprägnatpapiers, a support plate and the decorative paper according to the invention before a pressing;

Fig. 3

a sectional view of a Overlayimprägnatpapiers, a support plate, and the decorative paper according to the invention after the compression;

Fig. 4

a sectional view of the decorative paper according to the invention and the carrier plate after a pressing, wherein the Overlayimprägnatpapiers is replaced by a paint job; and

Fig. 5

a representation of the method for producing the decorative paper according to the invention.

This in Fig. 1 illustrated decor paper that is part of a laminate for a floor is provided with the reference numeral 100.

The decorative paper 100 has a plurality of layers, with the uppermost layer serving as a color layer 17, which is applied to the base paper layer 10 as part of a laminate production process in an upstream operation. In the in Fig. 1 Thus, a base paper layer 10 is shown, which is decorative printed with a printing ink 17. Alternatively, as is well known from the prior art, the base paper layer 10 can also be printed in one pass before impregnation as part of a laminate production process, wherein in a terminology used here, the surface of the base paper layer 10 facing the layer 17 is referred to as the top 11. Accordingly, the side facing away from the layer 17 of the base paper layer 10 is referred to as bottom 12. A further terminology can be made such that, in a laminate, the underside 12 is the side of the base paper layer 10 facing the carrier plate 18 ( Fig. 3 ).

The base paper layer 10 is due to the impregnation with resin 13 - in Fig. 1 illustrated dotted - soaked. In addition, goes out Fig. 1 show that the base paper layer 10 is provided with cellulose fibers 14. The base paper layer 10 with the layer 17 represents a conventional decorative paper, which is particularly integral part of laminates for floors.

In essential to the invention, this conventional decorative paper is extended by a further layer 16, as the decorative paper 100 on one side coated, impregnated, wherein the bottom 12 of the decorative paper 100 is provided with a coating order 15 in the form of a preferably thermosetting resin application.

In the context of a laminate production process, the additional one-sided impregnation of the base paper layer 10, i. H. the application of the additional layer 16 in the form of a resin application after impregnation and drying of a conventional decor paper done.

In the Fig. 1 shown layer 16, that is, the coating order 15, is as out Fig. 2 to 4 emerges, between the base paper layer 10 and the support plate 18 is arranged. Fig. 2 illustrates a layer sequence as it is preferably present in a laminate for a floor. In addition to the already in Fig. 1 shown and explained layers 10, 16, 17, the in Fig. 2 Shown embodiment of a layer sequence 200 in a laminate as the top layer 19 with a thermosetting resins, eg. In the form of melamine resins impregnated overlay paper, which in the in Fig. 1 embodiment shown to increase the abrasion resistance of the laminate floor in the layer 19 embedded abrasive particles 22 such. B. contains corundum particles. For improved resin uptake, the overlay paper may further comprise fiber-containing, in particular cellulose-containing material 21. As an alternative layers in the form of overlays are commonly used, which consist of two transparent melamine resin impregnated Consist of papers between which a base layer is enclosed. In Fig. 2 is between the layers 17 and 20 graphically given a distance that is intended to illustrate that the in FIG. 2 Layer sequence shown in a state before pressing with the support plate 18 is located.

Fig. 3 illustrates the state of the layer sequence 200 in a laminate after compression 23 with the support plate 18. As out Fig. 3 2, the compression 23 triggers a diffusion process such that particles of the resin 20 in the layer 19 as well as particles of the resin 13 in the layer 10 diffuse into the respectively underlying layers 17, 15. In addition, the particles in the layer 16, ie the resin particles of the coating application 15 diffuse as a result of compression 23 in the underlying support plate 18. This diffusion process is of importance, as this further processing of the laminate, for example. In the form of sawing or milling of the Laminates undergoes a simplification, and thus the solid, inner overall composite of the layer sequence 200 is achieved. In particular, the connection with the support plate 18 serving as carrier is thus produced

An alternative layer sequence 200 within the scope of the invention proceeds Fig. 4 out. This alternative layer sequence 200 is that in the Fig. 2 and 3 shown top layer 19 is replaced in the form of Overlayimprägnatpapiers by a top coat applied paint layer 25, which is interspersed with smaller corundum particles 26 to protect the decor paper 100. Between the lacquer layer 25 and the layer 17 there is a bonding agent 24, ie a so-called primer, which ensures increased adhesion between the lacquer layer 25 and the layer 17. Since the paint layer 25 is not like that in the Fig. 2 and 3 shown overlay impregnated paper is pressed together with the invention, one-sided impregnated decor paper with the support plate 18 sets, as Fig. 4 illustrates no diffusion process of the resin particles in the layer 17, a.

That in the Fig. 5 schematically illustrated method is used to produce the decorative paper according to the invention. The method can be divided into several functional areas, namely the functional areas impregnation of the base paper layer 27, drying of the impregnated base paper layer 27a in a dryer 43, coating of the impregnated and dried base paper layer 27a on one side, on the underside of the impregnated and dried base paper layer 27a a coating application / impregnation in the form of a thermosetting resin application and drying of the impregnate 27b thus obtained in a further dryer 48 in order to roll up the impregnate 27b on a roll 49.

The method begins with the processing of the base paper layer 27 from a role not shown here. The base paper layer 27 can be both a printed and an unprinted, d. H. act unifarbene layer. If the base paper is decorative printed, the unprinted back of the base paper layer of the subsequent impregnating roller 29 is facing. The base paper layer 27 is guided by means of the deflection rollers 28 along an impregnating roller 29, the lower part of which is immersed in a tub 30 filled with thermosetting resin, preferably urea 31. The roller 29 carries the thermosetting synthetic resin, preferably melamine resin and / or urea resin 31 in this way, on the underside of the base paper layer 27.

This one-sided coated with thermosetting synthetic resin base paper layer 27c then passes through the deflection roller 32 and the guide rollers 33, a so-called "breath zone" on which the with thermosetting Resin 31 impregnated base paper layer 27c also undergoes a smoothing.

The base paper layer 27c is then guided by means of the deflection rollers 36, 37 a certain distance, in order to then be guided along a scraper 34 or preferably a squeegee. Below the scraper or the squeegee is the drip pan 35. This takes up the laterally dissipated order surplus. The base paper layer 27a, which has now been so impregnated and doctored off, passes through the nip 40 between the metering rollers 38, 39 for the purpose of uniform metering.

Via further deflection rollers 41, 42, the now impregnated base paper layer 27a is fed to a dryer 43 in order to carry out a first drying process.

In a step essential to the invention, after drying of the impregnated, printed or unprinted base paper layer 27a, it is fed to the underside of an impregnating roller 45 by means of a further guide roller 44, which is immersed in a resin tub 45b filled with a thermosetting resin 45a. This application device, ie, the applicator roll 45 and the tub 45b filled with thermosetting resin 45a, coats the underside of the dried base paper 27a with a layer 27b having the resin 45a. The impregnate thus obtained, ie the previously dried and pre-impregnated base paper layer 27a, is subjected to a further drying process in a dryer 48, to be subsequently rolled up by means of the roll 49 or stacked into sheet-cut stacks (see FIG Fig. 5 not shown in the drawing).

In a further processing of the decorative paper 100 of the invention can be provided that the one-sided, for example, coated with a thermoset resin, already printed decorative paper together with a on the decorative top applied Overlayimprägnat is pressed together under pressure and temperature action with a wood material. Alternatively, the one-sided, for example, coated with aminoplast resin, already printed decorative paper can be pressed in the processing without Overlayimprägnat under pressure and temperature on a wood material, which subsequently undergoes a lacquer coating thus produced plate. In the context of the invention, it is advantageous that the layer 16 of the decorative paper 100 during processing, ie in the pressing always to the support plate 18 is aligned as a glue joint.

The present invention is not limited in its embodiment to the above-mentioned, preferred embodiments. Rather, a number of variants are conceivable, which make use of the illustrated solution even with fundamentally different types of execution. For example, in the Fig. 1 to 4 be shown differently configured layer sequences. Thus, instead of the layer 17 in the form of a color layer, a decor pressure may be provided. In addition, the in Fig. 5 shown process modifications insofar as modified in addition to various stages of the process of the base paper layer 27 antiblocking agent or acrylate resins are added. Furthermore, the impregnation roller or applicator roller 45 can be adapted or modified in its design of the surface design to the requirements of the order quality. Also, other application methods such as doctor blade application, anilox roller application, multi-roll application in a suitable embodiment are suitable for this purpose.

LIST OF REFERENCE NUMBERS

100

decorative paper

200

layer sequence

10

Base paper layer

11

top

12

bottom

13

resin

14

cellulose fibers

15

Coating application (impregnate)

16

layer

17

layer

18

support plate

19

top layer

20

layer

21

cellulosic material

22

abrasive particles

23

pressing

24

primer

25

paint layer

26

corundum

27

Base paper layer

27a

impregnated base paper layer

27b

layer

28

idler pulley

29

impregnation

30

tub

31

Thermosetting synthetic resin

32

deflecting

33

idler pulley

34

scraper

35

drip tray

36

idler pulley

37

idler pulley

38

metering

39

metering

40

nip

41

idler pulley

42

idler pulley

43

dryer

44

guide roller

45

Impregnating roller / applicator roll

45a

resin

45b

resin bath

48

dryer

49

role

Claims (16)

Decorative paper (100) for a laminate material, characterized in that the paper (100) is impregnated on one side, wherein the underside (12) of the paper (100) is impregnated. Decorative paper according to claim 1, characterized in that the underside (12) of the paper (100) is provided with an impregnate in the form of a coating order (15). Decorative paper according to claim 1 or 2, characterized in that the underside of the paper (12) is provided with a coating application (15). Decorative paper according to one of claims 1 to 3, characterized in that the paper (100) is printed unprinted or decorative. Decorative paper according to one of claims 2 to 4, characterized in that the coating application (15) is a plastic, preferably a thermosetting plastic, which preferably includes a synthetic resin. Decorative paper according to one of claims 2 to 4, characterized in that the coating order (15) includes a thermosetting resin. Decorative paper according to one of claims 2 to 6, characterized in that the coating order (15) includes an antiblocking agent. Decorative paper according to one of the preceding claims, characterized in that the upper side (11) of the paper (100) can be provided with a surface finish (25). Decorative paper according to one of claims 1 to 7, characterized in that the top side (11) of the paper (100) can be provided with a bonding agent (24) onto which a surface finish (25) can be applied. Decorative paper according to one of the preceding claims, characterized in that the unilaterally impregnated paper (100) can be pressed with a wood-based material panel (18). Decorative paper according to one of claims 1 to 7, characterized in that the one-sided impregnated paper (100) is compressible with an Overlayimprägnat. Laminate material with decorative paper (100) according to one of claims 1 to 11. Process for producing a decorative paper (100) according to one of Claims 1 to 11, comprising the following process steps: a) impregnation of a base paper layer (27); b) drying the layer (27a) impregnated in step a); c) coating the underside of the paper (27a) dried in step b) with a resin-comprising layer (27b). A method according to claim 13, characterized in that the layer (27b) is provided with melamine resin and / or acrylate resin and / or an antiblocking agent. A method according to claim 13 or 14, characterized in that stripped in step a), the top of the layer (27), in particular scraped off. Method according to one of claims 13 to 15, characterized in that in step a) with a solid resin content between 20% and 70% is impregnated.

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