EP2960369A1 - Procédé de fabrication de laminé - Google Patents

Procédé de fabrication de laminé Download PDF

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Publication number
EP2960369A1
EP2960369A1 EP14002167.6A EP14002167A EP2960369A1 EP 2960369 A1 EP2960369 A1 EP 2960369A1 EP 14002167 A EP14002167 A EP 14002167A EP 2960369 A1 EP2960369 A1 EP 2960369A1
Authority
EP
European Patent Office
Prior art keywords
layer
impregnate
impregnated
liquid medium
melamine 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.)
Pending
Application number
EP14002167.6A
Other languages
German (de)
English (en)
Inventor
Norbert Kalwa
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.)
Flooring Technologies Ltd
Original Assignee
Flooring Technologies Ltd
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 Flooring Technologies Ltd filed Critical Flooring Technologies Ltd
Priority to EP14002167.6A priority Critical patent/EP2960369A1/fr
Priority to CN201580033360.4A priority patent/CN106460345B/zh
Priority to RU2016138723A priority patent/RU2691045C2/ru
Priority to UAA201610054A priority patent/UA121466C2/uk
Priority to CA2947058A priority patent/CA2947058C/fr
Priority to PCT/EP2015/001195 priority patent/WO2015197164A1/fr
Priority to US15/302,820 priority patent/US10385512B2/en
Publication of EP2960369A1 publication Critical patent/EP2960369A1/fr
Pending legal-status Critical Current

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Classifications

    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H27/00—Special paper not otherwise provided for, e.g. made by multi-step processes
    • D21H27/18—Paper- or board-based structures for surface covering
    • D21H27/22—Structures being applied on the surface by special manufacturing processes, e.g. in presses
    • D21H27/26—Structures being applied on the surface by special manufacturing processes, e.g. in presses characterised by the overlay sheet or the top layers of the structures
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H17/00—Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
    • D21H17/03—Non-macromolecular organic compounds
    • D21H17/05—Non-macromolecular organic compounds containing elements other than carbon and hydrogen only
    • D21H17/07—Nitrogen-containing compounds
    • D21H17/08—Isocyanates
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H17/00—Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
    • D21H17/20—Macromolecular organic compounds
    • D21H17/33—Synthetic macromolecular compounds
    • D21H17/46—Synthetic macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • D21H17/47—Condensation polymers of aldehydes or ketones
    • D21H17/49—Condensation polymers of aldehydes or ketones with compounds containing hydrogen bound to nitrogen
    • D21H17/51—Triazines, e.g. melamine
    • 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
    • D21H19/00—Coated paper; Coating material
    • D21H19/10—Coatings without pigments
    • D21H19/14—Coatings without pigments applied in a form other than the aqueous solution defined in group D21H19/12
    • D21H19/24—Coatings without pigments applied in a form other than the aqueous solution defined in group D21H19/12 comprising macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • 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
    • D21H19/00—Coated paper; Coating material
    • D21H19/10—Coatings without pigments
    • D21H19/14—Coatings without pigments applied in a form other than the aqueous solution defined in group D21H19/12
    • D21H19/24—Coatings without pigments applied in a form other than the aqueous solution defined in group D21H19/12 comprising macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • D21H19/26—Aminoplasts
    • 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
    • D21H19/00—Coated paper; Coating material
    • D21H19/36—Coatings with pigments
    • D21H19/44—Coatings with pigments characterised by the other ingredients, e.g. the binder or dispersing agent
    • D21H19/62—Macromolecular organic compounds or oligomers thereof obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds

Definitions

  • the invention relates to a process for producing an impregnate having a cellulose layer which is impregnated with a melamine resin to form a core impregnation.
  • Impregnates are used in particular as precursors in the production of laminates.
  • Laminates are used, for example, in the wood-based panel industry for coating wood-based panels.
  • the cellulose layer is impregnated with a melamine resin which is thermally curable, so that the impregnate can be pressed with a wood-based panel or other impregnates, in particular special papers or kraft papers.
  • the finished impregnate is thus initially a precursor which is directly pressed in one or more layers on the wood-based panel to be coated, for example, a chipboard or medium density or high density fiberboard (MDF, HDF). After pressing, a chemically, thermally and mechanically highly resistant coating is obtained.
  • the impregnate can be pressed either in a short-cycle or in a continuous process with the wood-based panel.
  • impregnate and a process for producing the impregnate are described.
  • So-called impregnation channels are used as industrial plants for the production of the impregnates.
  • Continuous production is possible in these impregnation channels in that the cellulose layer passes through one or more trays filled with impregnating fluids.
  • impregnating fluid over rollers and doctor blade or sprayed on nozzles.
  • the still moist cellulose layer undergoes drying immediately thereafter, in order to evaporate the excess water and / or solvent to a defined residual moisture content and to obtain a dry, storage-stable and machine-processable impregnate.
  • the continuously running impregnate is either cut into sheets or wound into a roll.
  • the known melamine resin-based laminate floors are hard due to this coating, are perceived as cold, and create when walking a perceived as disturbing room sound.
  • WO 2011/082491 A1 describes the use of a water-thinnable polyurethane for the production of impregnated overlays, decor papers, underlays and counterwebs.
  • a two-stage process first a core impregnation and then a post-impregnation is carried out.
  • This relatively expensive polyurethane is used, which is about 10 to 15 more expensive than melamine resin. If an overlay is produced with this method, the cost of impregnation of the impregnate increases by a factor of 8 to 10. Since at least two impregnation channels are necessary, this impregnation can not be carried out on every impregnation plant.
  • impregnation / drying of paper-based webs with aqueous resins leads to swelling and shrinkage, the extent of which depends on the water content of the formulations and on the synthetic resin used.
  • special resins must be used, whereby the swelling-shrinkage behavior of the "normal" melamine impregnation deviates. This leads, in particular when the impregnate is used as decor paper, to problems if, during the pressing, a structure synchronous to the decoration (synchronous pore) is to be produced, because the embossing of the press plates usually depends on the decoration growth of a press Melamine impregnation is designed.
  • the invention is based, in particular, on the technical problem of modifying the lamination production technology known per se so that laminates with a warmer, softer and less noticeable coating are easy and safe to produce and, moreover, can easily be integrated into existing production processes. Furthermore, of course, the behavior towards mechanical stress such as shock or abrasion should not be degraded, but if possible even improved.
  • a generic method is characterized in that at least on one side of the core-impregnated cellulose layer, ie on its upper side and / or its underside, a layer of a liquid medium is applied with a proportion of isocyanate groups.
  • Isocyanate groups are highly reactive.
  • the isocyanate groups according to the invention either react with the OH group of the ⁇ -cellulose in the cellulose layer the NH group or the methylol group of the melamine resin of the core impregnation of the cellulose layer and therefore leads to a particularly effective anchoring on the surface of the core-impregnated cellulose layer. After later compression of the impregnate on a support into a laminate, this results in a coating which is haptically warmer and softer than a melamine resin layer. In floor laminates produced in this way, this also leads to a noise reduction. The behavior against mechanical stress such as impact or abrasion is not deteriorated compared to conventional coatings.
  • the liquid medium has a solids content of preferably 50% to 60%, with water as solvent.
  • water in addition to water, organic solvents or additives are also possible, for example dispersants, release agents, wetting agents, defoamers. Drying of the liquid medium has a coating-forming effect.
  • the liquid medium can also be designed with a 100% solids content, as a hotmelt.
  • Hotmelt is heated before being applied to the core-impregnated cellulose layer and melted to a liquid. During the subsequent solidification, a layer is formed. The layer formation can be accelerated by active cooling. Hotmelt is applied either by means of a slit gland or a spray application.
  • wear-inhibiting particles in particular corundum particles, are preferably either contained in the liquid medium and / or are sprayed onto the liquid medium, preferably before its layer formation.
  • the liquid medium or the hotmelt is applied in an amount of 50 to 300 g / m 2 .
  • At least one covering layer consisting of a UV varnish can be applied on the upper side, into which nanoparticles can also be mixed in order to further improve the micro-scratch resistance. It is also possible to admix antistatic agents and / or antibacterial agents.
  • the melamine resin may be pure melamine resin. Preferably, however, it is formed as a mixture of melamine resin and urea resin.
  • the impregnate can be used as overlay, backsheet, decorative paper and underlay.
  • the impregnate may be present as a sheet or roll goods.
  • the sole figure shows an impregnate with a cellulose layer 4, which can be used as decor paper, as an overlay, as a counter-pull and / or as an underlay.
  • This impregnate may be in the form of sheets or rolls.
  • the cellulose layer 4 is soaked in the core with a pure melamine resin or a melamine resin mixture of pure melamine resin and urea resin.
  • the cellulose layer 4 can be pulled through a bath or the resin can be rolled or sprayed on.
  • a one-sided impregnation by purging has proven to be particularly advantageous.
  • the cellulose layer 4 can be removed with a knife blade. After drying the impregnated cellulose layer 4 to a defined residual moisture, no melamine resin layers 3, 5 are formed on its upper side O and its underside U, but the core impregnation fills the cellulose layer 4.
  • a liquid medium containing isocyanate groups is applied.
  • the liquid medium has a solids content of preferably 50% to 60%, with water as solvent.
  • organic solvents or additives are also possible, for example dispersants, release agents, wetting agents, defoamers.
  • the dispersion applied in an amount of 50 to 300 g / m 2 is then dried to a layer 2.
  • a covering layer 1 comprising a UV varnish is applied to the upper side O of the layer 2.
  • This UV varnish preferably contains nanoparticles 7 based on silica for increasing the micro-scratch resistance.
  • the liquid medium may contain wear-inhibiting particles 6, in particular corundum particles, which are mixed either in the medium before application or after application to the
  • the hotmelt can additionally be applied to the underside U of the cellulose layer 4.
  • the hotmelt is heated before application, becomes liquid and then forms a layer 2 with isocyanate groups automatically on cooling.
  • wear-inhibiting particles 6, in particular corundum particles may have been admixed with the hotmelt or sprinkled on the top O of the liquid hotmelt after application.
  • the amount of the applied dispersion or of the applied hotmelt is about 50 to 300 g / m 2 solid.
  • the cover layer 1 may be added in addition to the nanoparticles 7 and antistatic agents and / or antibacterial agents. These agents may also be added to the liquid material or sprinkled onto the still liquid layer 1 after application.
  • the product marketed by Kleiberit under the name PUR HC717.5 can be used as the hotmelt.
  • the isocyanate groups in the hotmelt or in the dried dispersion are reactive and react with the OH group of the ⁇ -cellulose in the cellulose layer 4 and / or the methylol group of the melamine resin from the core-impregnated cellulose layer 4 to form a polyurethane and / or with the NH group to a urea derivative.
  • the reaction with water to amine and further reaction with free isocyanate groups to urea derivatives is possible.
  • an anchoring of the dried dispersion or the hot melt is achieved on the impregnate. This is compared to a conventional melamine resin softer, yet wear-resistant, haptic warmer and sound not so striking layer 2 is formed.
  • this impregnate When this impregnate is to be used as an overlay, it can be pressed on short-cycle presses in combination with conventional melamine resin-impregnated decorative papers and counterwebs. Since the isocyanate groups react with the melamine resin in the cellulose layer 4 and / or the ⁇ -cellulose in the cellulose layer 4, a composite of the individual layers sets in and via the melamine contained in the cellulose layer 4, the overlay with the other melamine resin-impregnated papers is established connected.
  • the cellulose layer 4 may be a paper, in particular a printed decorative paper.
  • a structure synchronous with the decoration can be embossed into the covering layer 1.
  • the engraved with the structure of press plates which are usually designed for a structure of melamine resin, can be used unchanged.
  • the impregnate thus prepared can be pressed into a laminate with a wood-based panel, such as an MDF or HDF panel, other impregnates, and especially specialty or kraft papers.
  • a wood-based panel such as an MDF or HDF panel
  • floor panels can be produced from the wood-based panel coated with one or more impregnates, which profiles are profiled on opposite side edges in such a way that several panels can be connected to one another and locked to one another.
EP14002167.6A 2014-06-24 2014-06-24 Procédé de fabrication de laminé Pending EP2960369A1 (fr)

Priority Applications (7)

Application Number Priority Date Filing Date Title
EP14002167.6A EP2960369A1 (fr) 2014-06-24 2014-06-24 Procédé de fabrication de laminé
CN201580033360.4A CN106460345B (zh) 2014-06-24 2015-06-15 用于层压体制造的方法
RU2016138723A RU2691045C2 (ru) 2014-06-24 2015-06-15 Способ изготовления ламината
UAA201610054A UA121466C2 (uk) 2014-06-24 2015-06-15 Спосіб виготовлення ламіната
CA2947058A CA2947058C (fr) 2014-06-24 2015-06-15 Procede de fabrication de stratifies
PCT/EP2015/001195 WO2015197164A1 (fr) 2014-06-24 2015-06-15 Procédé de fabrication de stratifiés
US15/302,820 US10385512B2 (en) 2014-06-24 2015-06-15 Laminate production method

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP14002167.6A EP2960369A1 (fr) 2014-06-24 2014-06-24 Procédé de fabrication de laminé

Publications (1)

Publication Number Publication Date
EP2960369A1 true EP2960369A1 (fr) 2015-12-30

Family

ID=50982745

Family Applications (1)

Application Number Title Priority Date Filing Date
EP14002167.6A Pending EP2960369A1 (fr) 2014-06-24 2014-06-24 Procédé de fabrication de laminé

Country Status (7)

Country Link
US (1) US10385512B2 (fr)
EP (1) EP2960369A1 (fr)
CN (1) CN106460345B (fr)
CA (1) CA2947058C (fr)
RU (1) RU2691045C2 (fr)
UA (1) UA121466C2 (fr)
WO (1) WO2015197164A1 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2022200882A1 (fr) * 2021-03-24 2022-09-29 Flooring Industries Limited, Sarl Panneau et procédé de fabrication de panneaux

Families Citing this family (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN108624242A (zh) * 2018-05-23 2018-10-09 广东鹏美森木业科技有限公司 一种瓷砖快速粘贴胶及其制作方法
EP3686008B1 (fr) * 2019-01-23 2021-06-23 Flooring Technologies Ltd. Procédé de fabrication d'un panneau multicouche résistant à l'abrasion et à l'eau et panneau fabriqué selon ledit procédé
EP3702172B1 (fr) * 2019-03-01 2022-04-20 Flooring Technologies Ltd. Procédé de fabrication d'un panneau structuré en surface multicouches et panneau fabriqué selon ledit procédé
CN112982033A (zh) * 2021-03-22 2021-06-18 佛山市西钢装饰材料有限公司 一种复合三聚氰胺纸的卷材

Citations (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0081967A1 (fr) * 1981-12-11 1983-06-22 Epsilon Development Limited Production de laminés
DE3925451C1 (en) * 1989-08-01 1990-09-06 Th. Goldschmidt Ag, 4300 Essen, De Decorative film of melamine-formaldehyde resin-coated paper - with outer coating of acrylate copolymer grafted with hardenable styrene-- or methacrylate-copolymer
WO1993025384A1 (fr) * 1992-06-08 1993-12-23 Weyerhaeuser Company Composites lamines en polyuree-cellulose, et procedes de fabrication
US5716676A (en) * 1992-10-29 1998-02-10 Bayer Aktiengesellschaft Aqueous coating compositions and their use for the preparation of coatings that are permeable to water vapor
WO2002008518A1 (fr) * 2000-07-21 2002-01-31 Fritz Egger Gmbh & Co. Impregnat, procede de fabrication, et utilisation de cet impregnat
WO2009077561A1 (fr) * 2007-12-17 2009-06-25 Technocell Dekor Gmbh & Co. Kg Papier décor imprégné comprimable, imprimable par le procédé à jet d'encre
WO2009158251A1 (fr) * 2008-06-26 2009-12-30 E. I. Du Pont De Nemours And Company Stratifiés de papier ayant des propriétés améliorées de nettoyage facile et de résistance à l’abrasion
WO2010088769A1 (fr) * 2009-02-03 2010-08-12 Clausi Robert N Matériaux stratifiés d'atténuation des sons
WO2011082491A1 (fr) 2010-01-07 2011-07-14 Clausi Robert N Compositions de planchers souples
EP2743094A1 (fr) * 2012-12-12 2014-06-18 Flooring Technologies Ltd. Procédé de fabrication d'une plaque comportant une couche de décor

Family Cites Families (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3928706A (en) * 1973-06-25 1975-12-23 Formica Int Wear-resistant decorative laminates and methods for producing same
US6375788B1 (en) * 1996-07-16 2002-04-23 Premark Rwp Holdings, Inc. Method of coating melamine resin on laminating paper
DE50208771D1 (de) * 2002-01-22 2007-01-04 Thermopal Gmbh Verfahren und Vorrichtung zum Imprägnieren von dünnen Schichten mit härtbaren Flüssigkeiten
KR200324825Y1 (ko) * 2003-05-06 2003-08-27 주식회사 엘지화학 고압수지 주입 천연 무늬목을 기재층에 적층한 방음기능강화마루
DE102011080300A1 (de) * 2011-08-02 2013-02-07 Surface Technologies Gmbh & Co. Kg Verfahren zur Herstellung einer dekorierten Wand-, Decken- oder Fußbodenplatte

Patent Citations (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0081967A1 (fr) * 1981-12-11 1983-06-22 Epsilon Development Limited Production de laminés
DE3925451C1 (en) * 1989-08-01 1990-09-06 Th. Goldschmidt Ag, 4300 Essen, De Decorative film of melamine-formaldehyde resin-coated paper - with outer coating of acrylate copolymer grafted with hardenable styrene-- or methacrylate-copolymer
WO1993025384A1 (fr) * 1992-06-08 1993-12-23 Weyerhaeuser Company Composites lamines en polyuree-cellulose, et procedes de fabrication
US5716676A (en) * 1992-10-29 1998-02-10 Bayer Aktiengesellschaft Aqueous coating compositions and their use for the preparation of coatings that are permeable to water vapor
WO2002008518A1 (fr) * 2000-07-21 2002-01-31 Fritz Egger Gmbh & Co. Impregnat, procede de fabrication, et utilisation de cet impregnat
DE10035924B4 (de) 2000-07-21 2006-04-27 Fritz Egger Gmbh & Co Imprägnat und Verfahren zur Herstellung und Verwendung des Imprägnats
WO2009077561A1 (fr) * 2007-12-17 2009-06-25 Technocell Dekor Gmbh & Co. Kg Papier décor imprégné comprimable, imprimable par le procédé à jet d'encre
WO2009158251A1 (fr) * 2008-06-26 2009-12-30 E. I. Du Pont De Nemours And Company Stratifiés de papier ayant des propriétés améliorées de nettoyage facile et de résistance à l’abrasion
WO2010088769A1 (fr) * 2009-02-03 2010-08-12 Clausi Robert N Matériaux stratifiés d'atténuation des sons
WO2011082491A1 (fr) 2010-01-07 2011-07-14 Clausi Robert N Compositions de planchers souples
EP2743094A1 (fr) * 2012-12-12 2014-06-18 Flooring Technologies Ltd. Procédé de fabrication d'une plaque comportant une couche de décor

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2022200882A1 (fr) * 2021-03-24 2022-09-29 Flooring Industries Limited, Sarl Panneau et procédé de fabrication de panneaux
BE1029240B1 (nl) * 2021-03-24 2022-10-24 Flooring Ind Ltd Sarl Panelen en methode om panelen te produceren

Also Published As

Publication number Publication date
US10385512B2 (en) 2019-08-20
CN106460345A (zh) 2017-02-22
UA121466C2 (uk) 2020-06-10
CA2947058C (fr) 2023-10-03
US20170096776A1 (en) 2017-04-06
RU2016138723A (ru) 2018-07-24
RU2691045C2 (ru) 2019-06-07
RU2016138723A3 (fr) 2018-11-06
CA2947058A1 (fr) 2015-12-30
WO2015197164A1 (fr) 2015-12-30
CN106460345B (zh) 2019-04-19

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