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
• • 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
  • E04F15/00—Flooring

Definitions

• the present invention relates to a method for producing a provided with a decorative layer of a decorative paper material plate.
• various papers such as e.g. Decorative paper, overlays, Gegenzugpapiere, Underlays, etc., first impregnated in a impregnation with a thermosetting resin, which usually contains water as a solvent.
• a thermosetting resin which usually contains water as a solvent.
• the various papers are then subsequently dried back to a defined moisture content of about 5-7% by weight.
• the papers so completely impregnated are pressed onto wood-based panels in a press in a short-cycle process.
• US 6,551,694 B1 discloses a method for producing a wood-based panel consisting of a support plate and a decor paper arranged on the support plate, comprising the steps of (a) providing the decor paper, (b) applying at least one resin as impregnating agent only to the decorative paper opposite the decor, wherein the amount of resin applied is between 40 and 70% based on the paper weight of the decorative paper, and wherein a melamine-, urea- or urethane-based resin is used as the impregnating agent, (c) providing the support plate, (d) applying at least one layer at least one adhesive on at least one side of the backing plate, and (e) placing the decorative paper with the impregnated opposite side of the decor on the side of the backing plate provided with the adhesive.
• Impregnated papers are usually pressed onto a carrier by means of KT (short-cycle press) technology in a press.
• KT short-cycle press
• this KT technology also has some disadvantages.
• the impregnated paper sheets are relatively brittle and may tear or break during processing.
• the production of the sheets is also prone to jeopardy.
• this method is also relatively expensive, since a total of three papers are used.
• a decorative paper is used in the manufacture of a material plate which is only partially impregnated, wherein preferably the entire surface of the non-printed underside of the decorative paper, i. the side opposite the visible side of the decorative paper is evenly provided with the impregnating resin.
• an aqueous impregnating resin is used as the impregnating resin on the back, i. applied to the non-decorative side of the decorative paper.
• the decor of the decorative paper can be applied by gravure and / or digital printing.
• the amount of resin applied to the opposite side of the decor paper is between 30 and 70% by weight, preferably between 40 and 60% by weight, more preferably 50% by weight, based on the paper weight of the decorative paper.
• 50 g of impregnating resin per m 2 of decorative paper paper weight: 80 g / m 2 , solids content impregnating resin: 50% by weight are applied.
• the decor paper impregnated on the opposite side of the decor has a swelling in the length in a range of 0.2 to 0.4% and in the width of 0.5 to 0.9% can.
• the values for fully impregnated papers are in the range of 0.4 to 0.9% in length and 1.2 to 1.8% in width.
• the amount of impregnating resin used is drastically reduced at this value added stage. This leads to a significantly lower capital commitment in the overall process. Also, the drying process is shortened due to the reduced amount of impregnating compared to fully impregnated decorative papers, since during the impregnation process less resin Wegwarmt and water must be evaporated, so that a higher production speed and thus an energy saving in the manufacturing process is possible.
• the decorative paper impregnated on one side has a better adhesion and a faster adhesion to the carrier plate compared to a dry decorative paper.
• the liquid resin or impregnating resin applied to the at least one side of the carrier plate causes a dissolution of the predried impregnating agent on the back side of the decorative paper, which allows faster bonding of the decorative paper to the carrier plate.
• the impregnating resin activates the impregnation and leads to a rapid caking and a slip-proof connection between the carrier plate and decorative paper. An additional glue line is not required.
• the decor paper impregnated on the side opposite the decor is dried to a moisture content of 3-10% by weight, preferably 5-7% by weight, particularly preferably 6% by weight. Drying can be done in a convection dryer or near infrared (NIR).
• NIR near infrared
• the one-sided and preferably full-surface impregnated decorative paper is rolled up on its underside. This allows storage of the partially impregnated decorative paper for further use.
• the decor paper impregnated on the side opposite the decor can be applied or pressed onto the carrier plate immediately or immediately after the impregnation.
• the application or Pressing the partially impregnated decorative paper on the carrier plate which was previously provided with the liquid resin or impregnating resin.
• impregnating resin according to the invention a melamine-formaldehyde resin, a melamine-urea resin or an acrylate resin having a solids content of 30-50% by weight, preferably 40-50% by weight, in particular having a solids content of 50% by weight.
• a melamine-formaldehyde resin As impregnating resins, which are to be applied to the at least one side of the support plate, a melamine-formaldehyde resin, a melamine-phenol-formaldehyde resin, a melamine-urea resin or an acrylate resin having a solids content of 55-80 wt %, preferably 60-70% by weight, particularly preferably applied by 60% by weight. Accordingly, the viscosity of the liquid resin applied to the support plate is higher than the resin used as the impregnating agent.
• the amount of the impregnating resin to be applied to the support plate is 30 to 70 g, preferably 50 g per m 2 of support plate.
• the impregnating resin contains the usual auxiliaries such as hardeners, wetting agents, defoamers, etc.
• the impregnating resin to be applied to the carrier plate is applied to the carrier plate by means of a roller and dried after application in order to evaporate part of the water. However, the drying takes place only so far that the impregnating resin still has enough tack to fix the partially impregnated decor paper.
• This further layer to be applied can consist only of a resin, or it is also possible to use a mixture containing the resin, natural and / or synthetic fibers, wear-reducing particles and optionally further additives.
• the liquid or impregnating resin to be applied to the decorative paper such as e.g. a melamine resin of the type mentioned above, has a solids content of 60-70% by weight, in particular of 60% by weight.
• the formulation of impregnating resin, fibers and abrasion-resistant particles is preferably applied in an amount of 50-80 g of solid resin / square meter. This applied to the top of the decorative paper mixture can then be dried in a dryer to a defined residual moisture. Again, the drying can be done in a convection dryer or by near infrared.
• This method can be repeated several times in other commissioned works and dryers, wherein in one variant abrasion-resistant particles are present in the resin formulation in the first two application units. In another variant, only one order of resin with corundum is provided.
• liquid resin liquid resin
• natural and / or synthetic resins natural and / or synthetic resins
• abrasion-resistant particles optionally further additives the application of a further mixture of impregnating resin, fibers, glass spheres and auxiliaries.
• a total of two to four further orders of this mixture can be made, so that in this case the formation of a so-called liquid overlay takes place.
• At least one overlay in particular a resin-impregnated overlay (overlay impregnate), is applied to this first application of the mixture of liquid resin or liquid resin, fibers, particles and optionally further additives.
• At least one overlay in particular a resin-impregnated overlay, after placing the decorative paper impregnated on the opposite side of the decor onto the carrier plate in an alternative further step f1).
• the natural and / or synthetic fibers are preferably selected from a group of bleached cellulose fibers or organic polymer fibers.
• the abrasion-resistant particles are preferably selected from the group comprising aluminum oxides, corundum, boron carbides, silicon dioxides, silicon carbides and glass beads, with corundum and glass beads being particularly preferred.
• At least one color pigment selected from a group comprising titanium dioxide, zinc oxides, iron oxide pigments or metallic effect pigments.
• the variability and the design options are unlimited.
• this at least one additive may be selected from a group comprising conductive substances, flame retardants, luminescent substances and metals.
• carbon fibers and nanoparticles, in particular carbon nanotubes are named as conductive substances.
• Typical flame retardants are selected from the group comprising phosphates, borates, in particular ammonium polyphosphate, tris (tri-bromneopentyl) phosphate, zinc borate or boric acid complexes of polyhydric alcohols.
• fluorescent and phosphorescent substances particular attention is drawn to zinc sulfite and alkaline earth aluminates.
• the layer structure of support plate, decor paper, and optionally further resin layers is then preferably pressed.
• the pressing of the layer structure preferably takes place in a continuous press.
• the pressing of the layer structure leads to the formation of a surface structure above the decoration, optionally in conformity with the decoration, in the form of a so-called "emboss in register".
• At least one counter-pull is applied to the opposite side of the carrier plate not provided with the decorative paper.
• the carrier plate consists of a wood material, or a wood material-plastic mixture, in particular chip, medium-density fiber (MDF), high-density fiber (HDF) - coarse chip (OSB) or plywood plates are preferred.
• MDF medium-density fiber
• HDF high-density fiber
• OSB coarse chip
• the coated by the present process plate is then transferred together with a Schmidtpapier in a short-cycle press and cured the synthetic resins at high pressure and high temperature, wherein, as already mentioned above, in a variant, the application of a Schutzoverlays in the form of an overlay impregnate is possible.
• the latter can also be done to achieve increased wear resistance. This may be necessary in particular when using the floor coverings in highly stressed objects.
• the material plates produced by the present method are preferably used as laminate panels.
• the present method offers a number of advantages:
• the partial impregnation or one-sided impregnation of the decorative paper leads to a lower capital commitment on this value chain.
• the partially-impregnated paper is already pre-swollen so as to reduce length and width repeat problems typically encountered with the use of dry decorative paper.
• the roll processing is significantly cheaper and the flexibility of production increases.
• Another advantage of the present method is its high variability, which is based on the later use of the products.
• a printing base paper (paper weight: 80 g / m 2 ) is unrolled by a unwinding device and printed by gravure and / or digital printing and then impregnated in the back with a melamine resin in an impregnator.
• a melamine resin in an impregnator.
• about 50 g of melamine resin / m 2 are applied with a solids content of about 50%.
• the paper is then dried in a convection dryer or by NIR (near-infrared) to a moisture content of about 6% by weight.
• NIR near-infrared
• the impregnate is then pressed in a continuous press on a melamine resin precoated plate (application rate: 50 g melamine resin / m 2 , solids content impregnating resin: 60 wt%).
• the melamine resin contained on the plate contains the usual auxiliaries (hardener, wetting agent, defoamer, etc.) and has been pre-dried after application with a roller by convection or NIR.
• a mixture of melamine resin (solids content impregnating resin: 60% by weight), cellulose and corundum in an amount of 50-80 g impregnating resin / m 2 - depending on the desired wear class - is then also applied to the decorative paper in the roll application.
• the mixture is dried in a convection dryer or by near infrared.
• a decorative paper (paper weight: 80 g / m 2 ) is unrolled by a unwinding device and impregnated at the back in an impregnator with a urea resin. About 50 g of urea resin / m 2 are applied (solids content: 50% by weight).
• the paper is then dried in a convection dryer or by NIR to a moisture content of about 6%.
• the one-sided impregnated paper is pressed in a continuous press on a melamine resin precoated plate (application rate: 50 g melamine resin / m 2 , solids content: 60% by weight).
• the melamine resin on the plate contains the usual auxiliaries (hardener, wetting agent, defoamer, etc.) and has been pre-dried after application with a roll by convection or NIR.
• the mixture is dried in a convection dryer or by near infrared.
• the moisture of the coating is about 6% by weight after the drying process.
• a completely resin-impregnated decor paper (resin application: 100% by weight) and a resin-impregnated overlay (paper weight: 30 g / m 2 , final weight: 150 g / m 2 ) is placed.
• corundum was a wear-inhibiting agent.
• a recycled paper (paper weight: 100 g / m 2 , resin application: 120% by weight) is used. The entire assembly is pressed in a KT press at 30 bar and 200 ° c.
• a strand of HDF boards is continuously coated with an impregnating resin based on melamine in roll application. 100 g of melamine resin / m 2 are applied (solids content: 60% by weight).
• the Tränkharzrezeptur contains the usual auxiliary materials such as hardener, wetting and release agent.
• the impregnating resin is pre-dried after application with the help of a convection dryer or NIR to evaporate a part of the water.
• the drying process need only be conducted to the point where the resin retains its stickiness or penetration into a paper.
• a dry decorative paper (paper weight: 80 g / m 2 ) is unrolled by a rolling device and rolled into the still flowable resin. It is ensured by several on the top of successively arranged rollers that no wrinkles or ripples occur in the paper.
• the paper is then pressed onto the melamine resin precoated plate in a continuous press.
• a mixture of melamine resin (solids content impregnating resin: 60% by weight), cellulose and corundum in an amount of 50-80 g impregnating resin / m 2 - depending on the desired wear class - is then also applied to the decorative paper in the roll application.
• the mixture is dried in a convection dryer or by near infrared. The moisture of the coating is about 6% by weight after the drying process.
• Embodiments 1 and 2 made according to the method of the present invention using a partially impregnated decorative paper differ in the product of Embodiment 3 made using a fully impregnated decorative paper in that they are in terms of their storage time significantly better behavior.
• a fully impregnated paper must be processed within a few months.
• the partially impregnated papers can still be used after one year.
• Embodiment 4 made with a dry decorative paper
• a unilateral impregnation according to the invention in a impregnation channel is much easier to accomplish than the "pressing in” of glue into the backside of a paper, as in the case of the dry decorative paper. This is made difficult by the various parameters (density of the paper, pigment content, etc.). In addition, there is significantly more time available for the impregnation process compared to pressing, which makes the process less critical.

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• Laminated Bodies (AREA)
• Paper (AREA)

Priority Applications (13)

Applications Claiming Priority (1)

Publications (2)

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• 2012
  • 2012-12-12 PL PL12196717T patent/PL2743094T3/pl unknown
  • 2012-12-12 EP EP12196717.8A patent/EP2743094B1/de active Active
  • 2012-12-12 ES ES12196717.8T patent/ES2543154T3/es active Active
• 2013
  • 2013-12-12 EP EP13811849.2A patent/EP2931527B1/de active Active
  • 2013-12-12 WO PCT/EP2013/076366 patent/WO2014090939A1/de active Application Filing
  • 2013-12-12 ES ES13811849T patent/ES2856879T3/es active Active
  • 2013-12-12 PL PL13811849T patent/PL2931527T3/pl unknown
  • 2013-12-12 US US14/651,280 patent/US9757974B2/en active Active
  • 2013-12-12 CN CN201380065276.1A patent/CN104870203B/zh active Active
  • 2013-12-12 RU RU2015126253A patent/RU2612647C9/ru active
  • 2013-12-12 UA UAA201506479A patent/UA111565C2/uk unknown
  • 2013-12-12 CA CA2893820A patent/CA2893820C/en active Active
  • 2013-12-12 BR BR112015012286A patent/BR112015012286A2/pt not_active IP Right Cessation

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