EP3034259A1 - Method for manufacturing a wooden work surface with decorative panel, in particular a wood-plastic compound material with decorative panel - Google Patents

Method for manufacturing a wooden work surface with decorative panel, in particular a wood-plastic compound material with decorative panel Download PDF

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Publication number
EP3034259A1
EP3034259A1 EP14198757.8A EP14198757A EP3034259A1 EP 3034259 A1 EP3034259 A1 EP 3034259A1 EP 14198757 A EP14198757 A EP 14198757A EP 3034259 A1 EP3034259 A1 EP 3034259A1
Authority
EP
European Patent Office
Prior art keywords
wood
plastic
press
laminate
plate
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.)
Granted
Application number
EP14198757.8A
Other languages
German (de)
French (fr)
Other versions
EP3034259B1 (en
Inventor
Norbert Dr. 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
Priority to EP14198757.8A priority Critical patent/EP3034259B1/en
Application filed by Flooring Technologies Ltd filed Critical Flooring Technologies Ltd
Priority to PL14198757T priority patent/PL3034259T3/en
Priority to PT141987578T priority patent/PT3034259T/en
Priority to ES14198757.8T priority patent/ES2642816T3/en
Priority to UAA201901546A priority patent/UA123960C2/en
Priority to PL15726020T priority patent/PL3215327T3/en
Priority to ES15726020T priority patent/ES2817085T3/en
Priority to JP2017542277A priority patent/JP6437128B2/en
Priority to UAA201705502A priority patent/UA119483C2/en
Priority to EP15726020.9A priority patent/EP3215327B1/en
Priority to PCT/EP2015/060622 priority patent/WO2016071007A1/en
Priority to PT157260209T priority patent/PT3215327T/en
Priority to CN201580060630.0A priority patent/CN107206620B/en
Priority to RU2017119722A priority patent/RU2667757C1/en
Priority to US15/524,457 priority patent/US10369721B2/en
Priority to CA2966674A priority patent/CA2966674C/en
Priority to CN201911219585.5A priority patent/CN111037700B/en
Publication of EP3034259A1 publication Critical patent/EP3034259A1/en
Application granted granted Critical
Publication of EP3034259B1 publication Critical patent/EP3034259B1/en
Priority to RU2018132176A priority patent/RU2766677C2/en
Priority to JP2018212342A priority patent/JP6817994B2/en
Priority to US16/452,031 priority patent/US11072087B2/en
Active legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
    • B27N7/00—After-treatment, e.g. reducing swelling or shrinkage, surfacing; Protecting the edges of boards against access of humidity
    • B27N7/005—Coating boards, e.g. with a finishing or decorating layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
    • B27N7/00—After-treatment, e.g. reducing swelling or shrinkage, surfacing; Protecting the edges of boards against access of humidity

Definitions

  • the present invention relates to a method for producing a laminate, in particular based on a wood-plastic composite, comprising the steps of: providing a large-sized wood-plastic composite sheet; Applying a decorative layer on at least the top of the large-sized plate and pressing under the action of pressure and temperature.
  • the invention further provides a laminate made by this process.
  • wood-based panels e.g. in the form of wood fiber boards in various configurations for use as floor laminate or for cladding walls or in the manufacture of furniture has long been known.
  • wood fiber boards in the form of medium density wood fiber boards (MDF boards), high density wood fiber boards (HDF boards), chipboard or OSB boards (oriented strand board) used which are obtained by pressing appropriate wood fibers or chips with a thermosetting plastic resin as a binder ,
  • a particular problem with the use of said wood fiber boards is the sensitivity of the wood fibers or wood chips used to high humidity and direct water contact. While this problem can be dealt with relatively easily in the case of furniture or interior products by means of constructional or technological measures, in the case of floor coverings, e.g. Laminate flooring based on wood or wood-based panels is often much more problematic.
  • Floor coverings based on wood or wood-based panels such as laminate flooring or engineered parquet quickly react to water contact with swelling and / or dimensional changes. This is caused, inter alia, by the effects of water-based care products, some of which are used very frequently and very intensively. Also, high humidity can trigger comparable processes.
  • the flooring is typically also in direct contact with the building parts such as concrete floors / screed or walls, which may also carry moisture in the flooring. For this reason, in the production of the above-mentioned wood-based products on low-source woods or wood-based materials used, which indeed reduce the problems described, but can not completely prevent. Partially come also inorganic support plates for the production of products with wooden surfaces for use, which can lead to Verklebungs-, processing or installation problems.
  • PVC polyvinyl chloride
  • WPC wood-plastic composites
  • These wood-plastic composites consist of a mixture of thermoplastics and wood shavings / wood fibers. In order for these composites to have improved water resistance, it is favorable if the plastic content is> 50%. So far, such plates could be surface finished only by lamination or gluing with foil or painting. However, such coatings do not have the high resistance such as laminate flooring surfaces.
  • thermoset surface is pressed in a short-cycle press on the surface of the wood-based material carrier in the form of impregnated papers or so-called liquid coatings.
  • the resin oligomers in the papers or the liquid coating crosslink under high pressure and high temperatures to form a three-dimensional network.
  • laminate floors are easy and quick to lay. Due to the tried and tested reproduction technique, they offer a large variety of décor variants as well as a wide range of surface structures due to the variation of the press plates used. These can also be synchronized with the decor details, so that a very realistic replica of wood or stone decors is possible.
  • laminate flooring has disadvantages and limitations.
  • laminate in wet rooms is limited. Even when used in other areas must Prevent the ingress of moisture.
  • quillvergüteten carrier plates or the like Even with quillvergüteten carrier plates or the like, a residual risk of adverse changes by influence to high humidity remains.
  • the present invention is therefore based on the technical object to produce a laminate floor with a thermoset surface, which is insensitive to moisture / water stress.
  • the good mechanical properties should be preserved.
  • the decorative surface should continue to be produced in a KT press.
  • a large-area carrier plate is needed, which is not damaged by the above-mentioned process steps and leads to good quality products.
  • a multi-stage process in particular a three-stage process, in which first of all a mixture of wood particles, eg in the form of wood fibers, and plastics, in particular thermoplastics, a pre-fleece or a damping mat with a low bulk density is produced.
  • This low bulk density batt is then compacted into a batt and then compacted on a double belt press under high pressure and high temperature and then cooled in a cold press.
  • the present method enables the production of wood-based panels in the form of wood-plastic composites (WPCs) in large Formats suitable for making backing plates for use as floor laminates, coupled with high productivity and thus lower costs.
  • WPCs wood-plastic composites
  • thermoplastic plastic in particular in the form of thermoplastic granules or plastic fibers in the wood particle-plastic mixture is used.
  • the thermoplastic resin is preferably selected from a group comprising polyethylene (PE), polypropylene (PP), polyvinyl chloride (PVC), polyester, polyethylene terephthalate (PET), polyamide (PA), polystyrene (PS), acrylonitrile-butadiene-styrene (ABS ), Polymethylmethacrylate (PMMA), polycarbonate (PC), polyetheretherketone (PEEK), polyisobutylene (PIB), polybutylene (PB), mixtures or copolymers thereof.
  • PE polyethylene
  • PP polypropylene
  • PVC polyvinyl chloride
  • PET polyethylene terephthalate
  • PA polyamide
  • PS polystyrene
  • ABS acrylonitrile-butadiene-styrene
  • PMMA Polymethylmethacrylate
  • PC polycarbonate
  • PEEK polyetheretherketone
  • PIB polyisobutylene
  • PB polybutylene
  • thermoplastic can be used in the form of plastic fibers.
  • the plastic fibers can be present as monocomponent or bicomponent fibers.
  • the thermally activatable plastic or binding fibers perform both a binding and a support function in the matrix of wood fibers or wood particles.
  • monocomponent fibers they are preferably made of polyethylene or other low melting point thermoplastics.
  • Bicomponent fibers are particularly preferably used. Biko fibers increase the stiffness of wood fiber boards and also reduce the creep experienced by thermoplastics (such as PVC flooring).
  • the biko fibers are typically made of a Tragfilament or a core fiber made of a plastic with higher temperature resistance, in particular polyester or polypropylene, which are coated or coated by a plastic having a lower melting point, in particular of polyethylene.
  • the shell or the jacket of the biko fibers allows melting of the wood particles together after melting or melting.
  • bicomponent fibers those based on thermoplastics such as PP / PE, polyester / PE or polyester / polyester are used.
  • a wood particle-plastic mixture which has a mixing ratio of wood particles Plastic between 90 wt% wood particles: 10 wt% plastics and 20 wt% wood particles: 80 wt% plastics, preferably between 70 wt% wood particles: 30 wt% plastics and 40 wt% wood particles: 60 wt% plastics.
  • a wood particle-plastic mixture is used, which has a mixing ratio of wood particles to plastic of about 50% by weight of wood particles: 50% by weight of plastic.
  • the wood particle plastic mixture used may comprise, by way of example, 44% by weight of wood fibers or wood particles and 56% by weight of biko fibers, for example polyethylene terephthalate / polyethylene terephtelate-coisophthalate fibers or PP / PE fibers.
  • the plastic component itself is also a mixture of different plastics.
  • a plastic mixture of 20% by weight of bicomponent fibers 80% by weight of PE fibers up to 80% by weight of bicomponent fibers: 20% by weight of PE fibers.
  • other compositions are possible.
  • lignocellulose-containing comminution products such as e.g. Wood fibers, wood chips or wood flour to understand.
  • wood fibers in particular dry wood fibers with a length of 1.0 mm to 20 mm, preferably 1.5 mm to 10 mm and a thickness of 0.05 mm to 1 mm are used.
  • the wood fiber moisture content of the fibers used is in a range between 5 and 15%, preferably 6 and 12% based on the total weight of the wood fibers. This is to be evaluated as a particular advantage over the older processes for the production of WPCs (for example extruder processes), since in these processes the wood fibers or particles would have to be dried to a significantly lower moisture content due to the process.
  • the wood particles used with respect to the mean grain diameter wherein the average grain diameter d50 between 0.05 mm and 1 mm, preferably 0.1 and 0.8 mm may be.
  • the individual components wood particles and plastic are intimately mixed in a mixer. Blending is also done by inputting into a blowpipe when using wood fibers as a component. Here is on the way from the expand the components to the storage bunker intensive mixing by the injected air as a means of transport.
  • the wood particle-plastic mixture for example, after weighing on a panel scale, evenly spread on a first conveyor belt over its width.
  • the amount of supplied wood particle-plastic mixture depends on the desired mat thickness and the desired density of the produced Vorvlieses.
  • Typical basis weights of the scattered pre-fleece can be in a range between 3,000 and 10,000 g / m 2 , preferably between 5,000 to 7,000 g / m 2 .
  • the width of the scattered fleece is determined by the width of the first conveyor belt, and may be, for example, in a range up to 3,000 mm, preferably 2,800 mm, particularly preferably up to 2,500 mm.
  • the Vorvlies After applying the wood particle-plastic mixture on a first conveyor belt to form a Vorvlieses, the Vorvlies is transferred in at least one first annealing oven for pre-compression.
  • the pre-fleece of wood particles and plastic is heated in the at least one annealing furnace to a temperature which corresponds to the melting temperature of the plastic used or above.
  • the temperatures in the annealing furnace may be between 130 and 200 ° C, preferably 150 and 180 ° C, particularly preferably 160 and 170 ° C.
  • the core temperature of the pre-fleece is preferably in a range between 100 and 150 ° C, particularly preferably at about 130 ° C.
  • the plastic material is melted, whereby an intimate bond between the plastic material, e.g. the plastic fibers is caused by the wood fibers and at the same time there is a compaction of Vorvlieses.
  • the tempering ovens are heated directly by hot air, for example.
  • the precompressed nonwoven after leaving the tempering furnace has a bulk density (or a density) between 40 and 200 kg / m 3 , preferably 60 and 150 kg / m 3 , particularly preferably between 80 and 120 kg / m 3 on.
  • the thickness of the pre-compressed nonwoven may be between 20 and 100 mm, preferably 30 and 50 mm, particularly preferably 35 and 45 mm.
  • the feed of the conveyor belt or conveyor belt in the annealing furnace in a range between 5 and 15 m / min, preferably between 6 and 12 m / min.
  • the precompressed nonwoven fabric After leaving the annealing furnace, the precompressed nonwoven fabric can be cooled and made up.
  • Typical packaging measures are e.g. the trimming of the web of the resulting waste, in particular the resulting edge strips can be reduced and returned to the process. Since the desired mixing ratio is given, the material can be fed directly into the fiber bunker.
  • the precompressed nonwoven is compressed in the at least one double belt press to a thickness between 2 and 20 mm, preferably 4 and 15 mm, particularly preferably 5 and 10 mm.
  • the temperature applied during the compaction of the fleece in the at least one double-belt press is between 150 and 250 ° C., preferably 180 and 230 ° C., preferably 200 and 220 ° C.
  • the pressure applied in the at least one double belt press may be between 2 MPa and 10 MPa, preferably 3 MPa and 8 MPa, particularly preferably 5 and 7 MPa.
  • the feed of the double belt press is between 5 and 15 m / min, preferably between 6 and 12 m / min.
  • the compacted wood-plastic composite sheet leaving the double belt press is introduced into at least one cooling press, in which cooling of the compacted wood-plastic composite sheet to temperatures between 10 and 100 ° C, preferably 15 and 70 ° C, particularly preferably 20 and 40 ° C.
  • a pressure is applied which is identical or at least almost identical to the pressure in the double belt press, i. in the cooling press, a pressure prevails between 2 MPa and 10 MPa, preferably 3 MPa and 8 MPa, particularly preferably 5 and 7 MPa.
  • the compacted wood-plastic composite panels After leaving the cooling press, the compacted wood-plastic composite panels have a thickness between 2 and 15 mm, preferably 3 and 12 mm, more preferably 4 and 10 mm and most preferably 4.5 to 5.5 mm.
  • the bulk density of the compacted wood-plastic composite panels after leaving the cooling press is in a range between 500 and 1500 kg / m 3 , preferably between 650 and 1300 kg / m 3 , particularly preferably between 800 and 1100 kg / m 3 .
  • the wood-based panels or wood-plastic composites (WPC) produced by the present method are characterized by a swelling of less than 5%, preferably less than 3%, particularly preferably less than 1%.
  • the wood-based panel in the form of a WPC has a profiling at least in an edge region of the panel, wherein the profile, for example, the introduction of a tongue and / or groove profile in an edge or side surface of the wood-plastic Composite sheet allows, whereby the thus obtained panels or wood-plastic composite panels can be interconnected and allow a floating laying and covering a floor.
  • Flame retardants, luminescent or antibacterial substances may be added to the wood particle / plastic mixture as suitable additives.
  • Suitable flame retardants may be selected from the group comprising phosphates, borates, in particular ammonium polyphosphate, tris (tri-bromneopentyl) phosphate, zinc borate or boric acid complexes of polyhydric alcohols.
  • UV-stabilizing compounds such as the so-called HALS compounds.
  • antifungicides and antibacterial agents i.a. Polyimines are used.
  • an inorganic filler e.g. Materials such as talc, chalk, titanium dioxide, or others that give the plate a specific color.
  • the variety of differently patterned decorative papers are no limits .
  • decorative papers with an impregnation such as a thermosetting Resin impregnation, used for producing the decorative layer on the wood-plastic composite panels.
  • the overlay ply is preferably implemented as a cellulosic layer that is filled or unfilled, i. H. can be equipped with particles of high hardness to increase the abrasion resistance.
  • an overlay paper is used, which is also impregnated with a thermosetting resin. It is particularly preferred if the impregnated overlay papers are additionally provided with abrasion-resistant particles.
  • the abrasion-resistant particles are preferably selected from the group consisting of aluminum oxides, boron carbides, silicon dioxides, silicon carbides and glass particles.
  • a counter-pull can be applied to the underside of the wood-plastic composite material plate.
  • the counter-pull is carried out as a cellulose layer which is impregnated.
  • the counter-pull may be embodied as paper impregnated with a thermosetting resin.
  • the layer structure of the counter-contact corresponds exactly to the layer structure and the respective layer thickness of the layer sequence of decorative and overlay layers applied on the upper side.
  • the decor, overlay and the Gegenzuglage are all designed as a cellulose layer. It is particularly preferred if the cellulose layers for the production of the decorative, overlay and the counteracting layer are impregnated with a thermosetting synthetic resin. Especially suitable for use in the process according to the invention are thermosetting synthetic resins which are useful for the production of laminates.
  • the thermosetting resin for the impregnation of the cellulose layers is therefore preferably selected from urea resin, phenolic resin, melamine resin or mixtures thereof.
  • the decorative and / or overlay layers and the backing with the large-sized wood-plastic composite material plate are pressed in a single step under the action of temperature and pressure in a short-cycle press and processed into a laminate.
  • Conventional short-cycle presses operate, for example, at a pressure of 30 to 60 kg / cm 2 , a temperature at the wood material surface of about 165 - 175 ° C and a pressing time of 6 to 12 seconds.
  • the short-cycle presses When using the wood-plastic composite panels according to the invention as support materials, the short-cycle presses preferably operate at 30 ° C to 40 ° C lower temperatures than in the production of laminates based on conventional wood fiber boards. In a particularly preferred embodiment, when using the wood-plastic composite panels of the invention, the short-cycle presses operate at a temperature of 140 ° C to 160 ° C, at the panel surface, most preferably at 150 ° C at the panel surface.
  • the pressing time of the short-cycle press is when using the wood-plastic composite plates according to the invention at 5 to 15 s, preferably 7 to 12 s, more preferably less than or equal to 10 s, such as 9, 8, 7 or 6 seconds ,
  • cooling must take place so that the structure of the wood-plastic composite panels is not destroyed. This can be done for example by cooling the plates directly at the outlet of the press by means of pre-cooled air. Another possibility is cooling by means of cooled rolls or in a press equipped for this purpose (cooling zone).
  • the reduced temperature and shorter pressing time of the short-cycle press have the advantage that unnecessary heat input into the carrier plate (composite material) is prevented and thus undesirable plasticization and undesirable deformations of the carrier plate can be avoided.
  • a structured press plate it is also possible to produce surface structures in at least one surface, preferably at least the upper side of the carrier material, such as a wood-plastic composite plate, which optionally can be designed to match the décor called decorsynchronous structure).
  • the surface structures are formed largely congruent to the decor. In this case we speak of embossed-in-register structures.
  • the structures in Form of pore structures that follow the grain.
  • the structures may be depressions in the area of joint fill lines enclosed by the decor.
  • the pressing temperatures When coating the plate, however, the pressing temperatures must be reduced by 30 - 40 ° C. Like the reduction of the pressing times below 10 seconds, this measure also serves to prevent an unnecessary introduction of heat into the carrier plate, which would lead to undesired plasticization and thus to deformations.
  • the wood-plastic composite carrier plate has a significantly reduced swelling compared to standard HDF or low-source HDF. These reach in the coated state in the edge swell test according to DIN EN 13329 with high melamine reinforcement of the glue used, edge swell values by about 7%.
  • the wood-plastic composite sheet according to the invention reaches edge swellings of ⁇ 4% in the coated state.
  • the invention further provides a laminate based on a wood-plastic composite as a carrier, which has been prepared by the process according to the invention.
  • the present invention is advantageous in several respects.
  • the standard technologies used to make conventional laminates can be used with only minor variations, such as temperature and press time of the short-cycle press. Large format plates can be optimally processed.
  • the coated wood-plastic composite panels have, as a result, a very low swelling upon exposure to moisture.
  • the laminates produced by the process according to the invention can be used in the furniture industry, for example for kitchen and work surfaces or restaurant counters, but especially for laminate flooring, ceiling and wall coverings.
  • the scope of the wood-based panels and laminates according to the invention, due to the improved properties is significantly wider than in conventional wood-based panels.
  • Example 1 Production of wood-plastic composite panels as a carrier
  • Wood fibers (44% by weight) and BiCo fibers (56% by weight, polyethylene terephthalate / polyethylene terephthalate-coisophthalate) were conveyed from bale openers into a mixing device. Subsequently, a pre-fleece was formed from the mixture of fibers in a scattering device (basis weight: 4,200 g / m 2 ), which was placed on a conveyor belt with a width of 2,800 mm. The feed of the conveyor belt was about 6 m / min.
  • the fleece was precompressed in a flow-through oven at temperatures of up to 160 ° C to a thickness of 35 mm.
  • the precompressed nonwoven reached a core temperature of approx. 130 ° C.
  • the precompressed nonwoven was compacted to a thickness of 5.2 mm in a double belt press at a production speed of 6 m / min.
  • the oil temperature in the forerun of the double belt press was 220 ° C.
  • the WPC formats were covered on the top with a decorative polypropylene film for floor applications and on the back with a backing based on a glued paper. From the formats mentioned above floorboards were produced, which are equipped on the side surfaces with connecting profiles in the manner of a tongue and groove. The panels thus obtained are suitable for covering a floor and are laid floating.
  • the impregnated papers were standard in terms of resin coverage, VC (volatile matter content) value and reactivity.
  • the coating was carried out at about 150 ° C (temperature on the product), 40 bar and 9 seconds press time. Subsequently, the coated plate was cooled and separated after a defined storage time on a floor road to planks with a glueless connection profile. Planks were removed from production and subjected to an edge swell test in accordance with DIN EN 13329. An edge swelling of 2.5% was determined after 24 hours of testing. After re-drying at room temperature, this went back to 0.5%.

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  • Life Sciences & Earth Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Wood Science & Technology (AREA)
  • Forests & Forestry (AREA)
  • Dry Formation Of Fiberboard And The Like (AREA)

Abstract

Die vorliegende Erfindung betrifft ein Verfahren zur Herstellung eines Laminats, insbesondere auf Basis eines Holz-Kunststoff-Verbundwerkstoffs, umfassend die Schritte: Bereitstellen einer großformatigen Holz-Kunststoff-Verbundwerkstoff-Platte; Aufbringen einer Dekorlage auf wenigstens die Oberseite der großformatigen Platte und Verpressen unter Wirkung von Druck und Temperatur. Die Erfindung stellt weiterhin diesem Verfahren hergestelltes Laminat bereit.The present invention relates to a method for producing a laminate, in particular based on a wood-plastic composite, comprising the steps of: providing a large-sized wood-plastic composite sheet; Applying a decorative layer on at least the top of the large-sized plate and pressing under the action of pressure and temperature. The invention further provides a laminate made by this process.

Description

Die vorliegende Erfindung betrifft ein Verfahren zur Herstellung eines Laminats, insbesondere auf Basis eines Holz-Kunststoff-Verbundwerkstoffs, umfassend die Schritte: Bereitstellen einer großformatigen Holz-Kunststoff-Verbundwerkstoff-Platte; Aufbringen einer Dekorlage auf wenigstens die Oberseite der großformatigen Platte und Verpressen unter Wirkung von Druck und Temperatur. Die Erfindung stellt weiterhin diesem Verfahren hergestelltes Laminat bereit.The present invention relates to a method for producing a laminate, in particular based on a wood-plastic composite, comprising the steps of: providing a large-sized wood-plastic composite sheet; Applying a decorative layer on at least the top of the large-sized plate and pressing under the action of pressure and temperature. The invention further provides a laminate made by this process.

Beschreibungdescription

Die Verwendung von Holzwerkstoffplatten, z.B. in Form von Holzfaserplatten in unterschiedlichen Ausgestaltungen zur Verwendung als Fußbodenlaminat oder zur Verkleidung von Wänden oder auch bei der Herstellung von Möbeln ist seit langem bekannt. So werden beispielsweise Holzfaserplatten in Form von mitteldichten Holzfaserplatten (MDF-Platten), hochdichten Holzfaserplatten (HDF-Platten), Spanplatten oder OSB-Platten (oriented strand board) verwendet, welche durch Verpressen entsprechender Holzfasern oder Späne mit einem duroplastischen Kunststoffharz als Bindemittel gewonnen werden.The use of wood-based panels, e.g. in the form of wood fiber boards in various configurations for use as floor laminate or for cladding walls or in the manufacture of furniture has long been known. Thus, for example, wood fiber boards in the form of medium density wood fiber boards (MDF boards), high density wood fiber boards (HDF boards), chipboard or OSB boards (oriented strand board) used, which are obtained by pressing appropriate wood fibers or chips with a thermosetting plastic resin as a binder ,

Ein besonderes Problem bei der Verwendung der genannten Holzfaserplatten besteht in der Empfindlichkeit der eingesetzten Holzfasern oder Holzspäne gegenüber hohen Luftfeuchten und direktem Wasserkontakt. Während dieses Problem bei Möbeln oder Produkten für den Innenausbau durch konstruktive oder technologische Maßnahmen relativ leicht beherrscht werden kann, ist dies bei Bodenbelägen z.B. Laminatfussböden auf der Basis von Holz oder Holzwerkstoffen häufig deutlich problematischer.A particular problem with the use of said wood fiber boards is the sensitivity of the wood fibers or wood chips used to high humidity and direct water contact. While this problem can be dealt with relatively easily in the case of furniture or interior products by means of constructional or technological measures, in the case of floor coverings, e.g. Laminate flooring based on wood or wood-based panels is often much more problematic.

Bodenbeläge auf der Basis von Holz oder Holzwerkstoffplatten wie Laminatboden oder Fertigparkett reagieren auf Wasserkontakt schnell mit Quellungen und/oder Dimensionsänderungen. Dies wird u.a. durch Einwirkungen von Pflegemitteln auf Wasserbasis hervorgerufen, welche teilweise sehr häufig und sehr intensiv verwendet werden. Auch können hohe Luftfeuchten vergleichbare Prozesse auslösen. Darüber hinaus steht der Bodenbelag typischerweise auch in einem direkten Kontakt mit den Gebäudeteilen wie z.B. Betondecken/Estrich oder Wänden, die ebenfalls Feuchtigkeit in dem Bodenbelag transportieren können. Aus diesem Grund wird bei der Herstellung der obengenannten Holzwerkstoffprodukte auf quellarme Hölzer oder Holzwerkstoffe zurückgegriffen, was zwar die beschriebenen Probleme mindern, aber nicht gänzlich verhindern kann. Teilweise kommen auch anorganische Trägerplatten zur Herstellung von Produkten mit Holzoberflächen zum Einsatz, wobei es hier zu Verklebungs-, Bearbeitungs- oder Verlegeproblemen kommen kann.Floor coverings based on wood or wood-based panels such as laminate flooring or engineered parquet quickly react to water contact with swelling and / or dimensional changes. This is caused, inter alia, by the effects of water-based care products, some of which are used very frequently and very intensively. Also, high humidity can trigger comparable processes. In addition, the flooring is typically also in direct contact with the building parts such as concrete floors / screed or walls, which may also carry moisture in the flooring. For this reason, in the production of the above-mentioned wood-based products on low-source woods or wood-based materials used, which indeed reduce the problems described, but can not completely prevent. Partially come also inorganic support plates for the production of products with wooden surfaces for use, which can lead to Verklebungs-, processing or installation problems.

Als Alternative zur Verwendung von Laminatböden mit dem genannten Quellungsproblem wurden in der Vergangenheit zunehmend Fußböden auf Basis von Polyvinylchlorid (PVC) eingesetzt, die ein sehr geringes bis gar keine Quellung aufweisen. Nachteilig bei der Verwendung von PVC-Fußböden ist allerdings deren hohe Kratzanfälligkeit und Kriechneigung, was insbesondere in hochfrequentierten Bereichen (wie z.B. Verkaufsbereichen) zu einer schnellen Abnutzung und Unansehnlichkeit des Fußbodenbelages führt bzw. den Untergrund durchtelegrafieren lässt.As an alternative to the use of laminate flooring with said swelling problem, floors based on polyvinyl chloride (PVC) have been increasingly used in the past, which have very little to no swelling. A disadvantage of using PVC floors, however, is their high susceptibility to scratching and creeping, which leads to rapid wear and unsightliness of the floor covering or, in particular, in highly frequented areas (such as sales areas).

Andere Trägerplatten, die eine sehr geringe Wasserempfindlichkeit besitzen sind z. B. Holz-Kunststoff-Verbundwerkstoffe (wood-plastic-composites, WPC). Diese Holz-Kunststoff-Verbundwerkstoffe bestehen aus einem Gemisch von thermoplastischen Kunststoffen und Holzspänen/Holzfasern. Damit diese Verbundwerkstoffe eine verbesserte Wasserfestigkeit besitzen, ist es günstig, wenn der Kunststoffanteil > 50% ist. Bisher konnten derartige Platten nur durch Kaschierung oder Bekleben mit Folie oder Lackieren oberflächenveredelt werden. Derartige Beschichtungen besitzen aber nicht die hohe Beanspruchbarkeit wie Laminatboden-Oberflächen.Other carrier plates, which have a very low water sensitivity are z. B. wood-plastic composites (WPC). These wood-plastic composites consist of a mixture of thermoplastics and wood shavings / wood fibers. In order for these composites to have improved water resistance, it is favorable if the plastic content is> 50%. So far, such plates could be surface finished only by lamination or gluing with foil or painting. However, such coatings do not have the high resistance such as laminate flooring surfaces.

Der Produktvorteil von Laminatböden, dass sie mit ihrer duroplastischen Oberfläche besonders widerstandsfähig gegenüber chemischen und mechanischen Beanspruchungen sind, ist ein Hauptgrund für deren Markterfolg. Die duroplastische Oberfläche wird in einer Kurztakt-Presse auf die Oberfläche des Holzwerkstoffträgers in Form von imprägnierten Papieren oder sogenannten Flüssigbeschichtungen aufgepresst. Dabei vernetzen die Harzoligomeren in den Papieren bzw. der Flüssigbeschichtung unter hohem Druck und hohen Temperaturen zu einem dreidimensionalen Netzwerk.The product advantage of laminate flooring, which with its thermoset surface is particularly resistant to chemical and mechanical stress, is a major reason for its market success. The thermoset surface is pressed in a short-cycle press on the surface of the wood-based material carrier in the form of impregnated papers or so-called liquid coatings. The resin oligomers in the papers or the liquid coating crosslink under high pressure and high temperatures to form a three-dimensional network.

Zudem sind Laminatböden einfach und schnell zu verlegen. Sie bieten wegen der erprobten Reproduktionstechnik eine große Fülle an Dekorvarianten sowie durch die Variation der verwendeten Pressbleche eine große Bandbreite an Oberflächenstrukturen. Diese können auch mit den Dekordetails synchronisiert werden, sodass eine sehr realistische Nachbildung von Holz- oder Steindekoren möglich ist.In addition, laminate floors are easy and quick to lay. Due to the tried and tested reproduction technique, they offer a large variety of décor variants as well as a wide range of surface structures due to the variation of the press plates used. These can also be synchronized with the decor details, so that a very realistic replica of wood or stone decors is possible.

Die Verwendung von Laminatböden hat jedoch Nachteile und Grenzen. So ist Laminat in Feuchträumen nur begrenzt einsetzbar. Auch bei Verwendung in anderen Bereichen muss dem Eindringen von Feuchtigkeit vorgebeugt werden. Die Pflege von Laminatböden beispielsweise darf nicht zu feucht erfolgen. Auch bei quellvergüteten Trägerplatten oder ähnlichem bleibt ein Restrisiko nachteiliger Veränderungen durch Einfluss zu hoher Feuchte bestehen.However, the use of laminate flooring has disadvantages and limitations. Thus, laminate in wet rooms is limited. Even when used in other areas must Prevent the ingress of moisture. The care of laminate floors, for example, must not be too moist. Even with quillvergüteten carrier plates or the like, a residual risk of adverse changes by influence to high humidity remains.

Der vorliegenden Erfindung liegt daher die technische Aufgabe zu Grunde, einen Laminatboden mit einer duroplastischen Oberfläche herzustellen, der gegenüber einer Beanspruchung durch Feuchtigkeit/Wasser unempfindlich ist. Dabei sollen die guten mechanischen Eigenschaften erhalten bleiben. Gleichzeitig soll die Herstellung der dekorativen Oberfläche weiterhin in einer KT-Presse erfolgen. Dazu wird eine großflächige Trägerplatte benötigt, die durch die oben angesprochenen Verfahrensschritte nicht geschädigt wird und zu qualitativ guten Produkten führt.The present invention is therefore based on the technical object to produce a laminate floor with a thermoset surface, which is insensitive to moisture / water stress. The good mechanical properties should be preserved. At the same time, the decorative surface should continue to be produced in a KT press. For this purpose, a large-area carrier plate is needed, which is not damaged by the above-mentioned process steps and leads to good quality products.

Gelöst wird diese Aufgabe durch den Einsatz einer großformatigen Holz-Kunststoff-Verbundwerkstoff-Platte als Trägermaterial.This problem is solved by the use of a large-format wood-plastic composite panel as a carrier material.

Holz-Kunststoff-Verbundwerkstoff-Platten können beispielsweise, nach einem Verfahren hergestellt werden, dass die folgenden Schritte umfasst:

  • Aufbringen eines Gemisches aus Holzpartikeln und Kunststoff auf ein erstes Transportband unter Ausbildung eines Vorvlieses und Einführen des Vorvlieses in mindestens einen ersten Temperofen zum Vorverdichten;
  • Überführen des vorverdichteten Vlieses in mindestens eine Doppelbandpresse zum weiteren Verdichten zu einer Holz-Kunststoff-Verbundwerkstoff-Platte; und
  • Abkühlen der verdichteten Holz-Kunststoff-Verbundwerkstoff-Platte in mindestens einer Kühlpresse.
For example, wood-plastic composite panels can be made by a process that includes the following steps:
  • Applying a mixture of wood particles and plastic on a first conveyor belt to form a Vorvlieses and introducing the Vorvlieses in at least one first annealing furnace for pre-compression;
  • Transferring the precompacted web into at least one double belt press for further densification into a wood-plastic composite board; and
  • Cool the compacted wood-plastic composite panel in at least one cooling press.

Es wird demnach ein mehrstufiger Prozess, insbesondere ein dreistufiger Prozess bereitgestellt, in welchem zunächst aus einem Gemisch von Holzpartikeln, z.B. in Form von Holzfasern, und Kunststoffen, insbesondere thermoplastischen Kunststoffen, ein Vorvlies bzw. eine Dämpfstoffmatte mit einer niedrigen Rohdichte hergestellt wird. Dieses Vorvlies mit einer niedrigen Rohdichte wird anschließend zu einem Vlies verdichtet und dann auf einer Doppelbandpresse unter hohem Druck und hoher Temperatur verdichtet und anschließend in einer Kühlpresse abgekühlt. Das vorliegende Verfahren ermöglicht die Herstellung von Holzwerkstoffplatten in Form von Holz-Kunststoff-Verbundwerkstoffen (WPCs) in großen Formaten, die sich zur Herstellung von Trägerplatten zur Verwendung als Fußbodenlaminate eignen, verbunden mit einer hohen Produktivität und somit niedrigeren Kosten.Accordingly, a multi-stage process, in particular a three-stage process, is provided, in which first of all a mixture of wood particles, eg in the form of wood fibers, and plastics, in particular thermoplastics, a pre-fleece or a damping mat with a low bulk density is produced. This low bulk density batt is then compacted into a batt and then compacted on a double belt press under high pressure and high temperature and then cooled in a cold press. The present method enables the production of wood-based panels in the form of wood-plastic composites (WPCs) in large Formats suitable for making backing plates for use as floor laminates, coupled with high productivity and thus lower costs.

In einer Ausführungsform des vorliegenden Verfahrens wird ein thermoplastischer Kunststoff, insbesondere in Form von thermoplastischen Granulaten oder Kunststofffasern in dem Holzpartikel-Kunststoff-Gemisch verwendet.In one embodiment of the present method, a thermoplastic plastic, in particular in the form of thermoplastic granules or plastic fibers in the wood particle-plastic mixture is used.

Der thermoplastische Kunststoff ist bevorzugter Weise ausgewählt aus einer Gruppe enthaltend Polyethylen (PE), Polypropylen (PP), Polyvinylchlorid (PVC), Polyester, Polyethylenterephthalat (PET), Polyamid (PA), Polystyrol (PS), Acrylnitril-Butadien-Styrol (ABS), Polymethylmethacrylat (PMMA), Polycarbonat (PC), Polyetheretherketon (PEEK), Polyisobutylen (PIB), Polybutylen (PB), Mischungen oder Copolymerisate davon. Insbesondere ist es bevorzugt, wenn als thermoplastischer Kunststoff PE, PP, PVC oder eine Mischung davon eingesetzt wird.The thermoplastic resin is preferably selected from a group comprising polyethylene (PE), polypropylene (PP), polyvinyl chloride (PVC), polyester, polyethylene terephthalate (PET), polyamide (PA), polystyrene (PS), acrylonitrile-butadiene-styrene (ABS ), Polymethylmethacrylate (PMMA), polycarbonate (PC), polyetheretherketone (PEEK), polyisobutylene (PIB), polybutylene (PB), mixtures or copolymers thereof. In particular, it is preferred if PE, PP, PVC or a mixture thereof is used as thermoplastic material.

Wie oben erwähnt, kann der thermoplastische Kunststoff in Form von Kunststofffasern eingesetzt werden. Die Kunststofffasern können dabei als Monokomponenten- oder als Bikomponentenfasern vorliegen. Die thermisch aktivierbaren Kunststoff- bzw. Bindefasern führen in der Matrix aus Holzfasern bzw. Holzpartikel sowohl eine Binde- als auch eine Stützfunktion aus. Werden Monokomponentenfasern verwendet, bestehen diese bevorzugt aus Polyethylen oder anderen thermoplastischen Kunststoffen mit niedrigem Schmelzpunkt.As mentioned above, the thermoplastic can be used in the form of plastic fibers. The plastic fibers can be present as monocomponent or bicomponent fibers. The thermally activatable plastic or binding fibers perform both a binding and a support function in the matrix of wood fibers or wood particles. When monocomponent fibers are used, they are preferably made of polyethylene or other low melting point thermoplastics.

Bikomponentenfasern (auch als Biko-Stützfasern bezeichnet) werden besonders bevorzugt eingesetzt. Biko-Fasern erhöhen die Steifigkeit von Holzfaserplatten und verringern auch die bei thermoplastischen Kunststoffen (wie z.B. PVC-Böden) anzutreffende Kriechneigung.Bicomponent fibers (also referred to as Biko support fibers) are particularly preferably used. Biko fibers increase the stiffness of wood fiber boards and also reduce the creep experienced by thermoplastics (such as PVC flooring).

Die Biko-Fasern bestehen typischerweise aus einem Tragfilament oder auch einer Kernfaser aus einem Kunststoff mit höherer Temperaturbeständigkeit, insbesondere Polyester oder Polypropylen, die von einem Kunststoff mit einem niedrigeren Schmelzpunkt, insbesondere aus Polyethylen, umhüllt bzw. ummantelt sind. Die Hülle bzw. der Mantel der Biko-Fasern ermöglicht nach Aufschmelzen bzw. Anschmelzen eine Vernetzung der Holzpartikel miteinander. Vorliegend werden insbesondere als Bikomponentenfasern solche auf der Basis von Thermoplasten wie PP/PE, Polyester/PE oder Polyester/Polyester verwendet.The biko fibers are typically made of a Tragfilament or a core fiber made of a plastic with higher temperature resistance, in particular polyester or polypropylene, which are coated or coated by a plastic having a lower melting point, in particular of polyethylene. The shell or the jacket of the biko fibers allows melting of the wood particles together after melting or melting. In the present case, in particular as bicomponent fibers, those based on thermoplastics such as PP / PE, polyester / PE or polyester / polyester are used.

In einer weiteren Ausführungsform des vorliegenden Verfahrens wird ein Holzpartikel-Kunststoff-Gemisch verwendet, welches ein Mischungsverhältnis von Holzpartikeln zu Kunststoff zwischen 90 Gew% Holzpartikel : 10 Gew% Kunststoffe und 20 Gew% Holzpartikel : 80 Gew% Kunststoffe, bevorzugt zwischen 70 Gew% Holzpartikel : 30 Gew% Kunststoffe und 40 Gew% Holzpartikel : 60 Gew% Kunststoffe umfasst. In einer bevorzugten Ausführungsform der Erfindung wird ein Holzpartikel-Kunststoff-Gemisch verwendet, welches ein Mischungsverhältnis von Holzpartikeln zu Kunststoff von etwa 50 Gew% Holzpartikel : 50 Gew% Kunststoff aufweist. Das verwendete Holzpartikel-Kunststoffgemisch kann beispielhaft 44 Gew% Holzfasern bzw. Holzpartikel und 56 Gew% Biko-Fasern, z.B. Polyethylenterephthalat/Polyethylenterephtelat-Coisophtalat-Fasern oder PP/PE-Fasern aufweisen.In a further embodiment of the present method, a wood particle-plastic mixture is used which has a mixing ratio of wood particles Plastic between 90 wt% wood particles: 10 wt% plastics and 20 wt% wood particles: 80 wt% plastics, preferably between 70 wt% wood particles: 30 wt% plastics and 40 wt% wood particles: 60 wt% plastics. In a preferred embodiment of the invention, a wood particle-plastic mixture is used, which has a mixing ratio of wood particles to plastic of about 50% by weight of wood particles: 50% by weight of plastic. The wood particle plastic mixture used may comprise, by way of example, 44% by weight of wood fibers or wood particles and 56% by weight of biko fibers, for example polyethylene terephthalate / polyethylene terephtelate-coisophthalate fibers or PP / PE fibers.

Es ist ebenfalls vorstellbar, dass der Kunststoffanteil selbst auch ein Gemisch von verschiedenen Kunststoffen ist. So kann ein Kunststoffgemisch aus 20 Gew.% Bikomponentenfasern : 80 Gew% PE-Fasern bis zu 80 Gew.% Bikomponentenfasern : 20 Gew% PE-Fasern bestehen. Generell sind auch andere Zusammensetzungen möglich. Durch die Veränderung der Zusammensetzung der Kunststoffkomponente kann die zur Verdichtung des Vorvlieses bzw. Vlieses benötigte Temperatur verändert und angepasst werden.It is also conceivable that the plastic component itself is also a mixture of different plastics. Thus, a plastic mixture of 20% by weight of bicomponent fibers: 80% by weight of PE fibers up to 80% by weight of bicomponent fibers: 20% by weight of PE fibers. In general, other compositions are possible. By changing the composition of the plastic component, the temperature required for densifying the pre-fleece or fleece can be changed and adjusted.

Unter den vorliegend veränderten Holzpartikeln sind lignocellulosehaltige Zerkleinerungsprodukte wie z.B. Holzfasern, Holzspäne oder auch Holzmehl zu verstehen. Im Falle der Verwendung von Holzfasern kommen insbesondere trockene Holzfasern mit einer Länge von 1,0 mm bis 20 mm, bevorzugt 1,5 mm bis 10 mm und einer Dicke von 0,05 mm bis 1 mm zum Einsatz. Die Holzfaserfeuchte der verwendeten Fasern liegt dabei in einem Bereich zwischen 5 und 15 %, bevorzugt 6 und 12 % bezogen auf das Gesamtgewicht der Holzfasern. Dies ist als besonderer Vorteil gegenüber den älteren Verfahren zur Herstellung von WPC's (z.B.: Extruderverfahren) zu werten, da bei diesen die Holzfasern oder -partikel prozessbedingt auf eine deutlich niedrigere Holzfeuchte getrocknet werden müssten. Der Wassergehalt muss dort meist unter einem Prozent liegen.Among the presently modified wood particles are lignocellulose-containing comminution products such as e.g. Wood fibers, wood chips or wood flour to understand. In the case of the use of wood fibers, in particular dry wood fibers with a length of 1.0 mm to 20 mm, preferably 1.5 mm to 10 mm and a thickness of 0.05 mm to 1 mm are used. The wood fiber moisture content of the fibers used is in a range between 5 and 15%, preferably 6 and 12% based on the total weight of the wood fibers. This is to be evaluated as a particular advantage over the older processes for the production of WPCs (for example extruder processes), since in these processes the wood fibers or particles would have to be dried to a significantly lower moisture content due to the process. The water content there usually has to be less than one percent.

Es ist ebenfalls möglich, die verwendeten Holzpartikel in Bezug auf den mittleren Korndurchmesser zu bestimmen, wobei der mittlere Korndurchmesser d50 zwischen 0,05 mm und 1 mm, bevorzugt 0,1 und 0,8 mm betragen kann.It is also possible to determine the wood particles used with respect to the mean grain diameter, wherein the average grain diameter d50 between 0.05 mm and 1 mm, preferably 0.1 and 0.8 mm may be.

Entsprechend der gewünschten Zusammensetzung des Holzpartikel-Kunststoff-Gemisches werden die einzelnen Komponenten (Holzpartikel und Kunststoff) in einem Mischer innig vermischt. Eine Vermischung ist bei der Verwendung von Holzfasern als eine Komponente auch durch Eingeben in eine Blasleitung erfolgen. Hier erfolgt auf dem Weg von der Zugabe der Komponenten bis zum Vorratsbunker eine intensive Vermischung durch die eingeblasene Luft als Transportmittel.According to the desired composition of the wood particle-plastic mixture, the individual components (wood particles and plastic) are intimately mixed in a mixer. Blending is also done by inputting into a blowpipe when using wood fibers as a component. Here is on the way from the encore the components to the storage bunker intensive mixing by the injected air as a means of transport.

Aus dem Vorratsbunker wird das Holzpartikel-Kunststoff-Gemisch, z.B. nach Abwiegen auf einer Flächenwaage, auf ein erstes Transportband über seine Breite gleichmäßig aufgestreut. Die Menge an zugeführtem Holzpartikel-Kunststoff-Gemisch richtet sich nach der gewünschten Mattenstärke und der gewünschten Rohdichte des herzustellenden Vorvlieses. Typische Flächengewichte des gestreuten Vorvlieses können dabei in einem Bereich zwischen 3.000 und 10.000 g/m2, bevorzugt zwischen 5.000 bis 7.000 g/m2, liegen. Wie bereits erwähnt wird die Breite des gestreuten Vorvlieses durch die Breite des ersten Transportbandes bestimmt, und kann z.B. in einem Bereich bis zu 3.000 mm, bevorzugt 2.800 mm, insbesondere bevorzugt bis zu 2.500 mm liegen.From the storage bunker, the wood particle-plastic mixture, for example, after weighing on a panel scale, evenly spread on a first conveyor belt over its width. The amount of supplied wood particle-plastic mixture depends on the desired mat thickness and the desired density of the produced Vorvlieses. Typical basis weights of the scattered pre-fleece can be in a range between 3,000 and 10,000 g / m 2 , preferably between 5,000 to 7,000 g / m 2 . As already mentioned, the width of the scattered fleece is determined by the width of the first conveyor belt, and may be, for example, in a range up to 3,000 mm, preferably 2,800 mm, particularly preferably up to 2,500 mm.

Nach dem Aufbringen des Holzpartikel-Kunststoff-Gemisches auf ein erstes Transportband unter Ausbildung eines Vorvlieses, wird das Vorvlies in mindestens einen ersten Temperofen zum Vorverdichten überführt. In einer besonders bevorzugten Ausführungsform des Verfahrens wird das Vorvlies aus Holzpartikeln und Kunststoff in dem mindestens einen Temperofen auf eine Temperatur erhitzt, die der Schmelztemperatur des verwendeten Kunststoffes entspricht oder darüber liegt.After applying the wood particle-plastic mixture on a first conveyor belt to form a Vorvlieses, the Vorvlies is transferred in at least one first annealing oven for pre-compression. In a particularly preferred embodiment of the method, the pre-fleece of wood particles and plastic is heated in the at least one annealing furnace to a temperature which corresponds to the melting temperature of the plastic used or above.

Die Temperaturen im Temperofen können zwischen 130 und 200°C, bevorzugt 150 und 180°C, insbesondere bevorzugt 160 und 170°C liegen. Die Kerntemperatur des Vorvlieses liegt bevorzugt in einem Bereich zwischen 100 und 150°C, insbesondere bevorzugt bei ca. 130°C. Während des Erhitzens im Temperofen erfolgt ein Anschmelzen des Kunststoffmaterials, wodurch eine innige Verbindung zwischen dem Kunststoffmaterial wie z.B. den Kunststofffasern mit den Holzfasern hervorgerufen wird und gleichzeitig eine Verdichtung des Vorvlieses erfolgt. Dabei gilt, je höher die Kerntemperatur des Vorvlieses desto schneller kann die Presse gefahren werden, da der Verdichtungsprozess beschleunigt wird.The temperatures in the annealing furnace may be between 130 and 200 ° C, preferably 150 and 180 ° C, particularly preferably 160 and 170 ° C. The core temperature of the pre-fleece is preferably in a range between 100 and 150 ° C, particularly preferably at about 130 ° C. During heating in the annealing furnace, the plastic material is melted, whereby an intimate bond between the plastic material, e.g. the plastic fibers is caused by the wood fibers and at the same time there is a compaction of Vorvlieses. The higher the core temperature of the pre-fleece, the faster the press can be driven because the compaction process is accelerated.

Die Temperöfen werden beispielsweise durch Heißluft direkt beheizt.The tempering ovens are heated directly by hot air, for example.

In einer weiteren Ausführungsform des vorliegenden Verfahrens weist das vorverdichtete Vlies nach Austritt aus dem Temperofen eine Rohdichte (bzw. ein Raumgewicht) zwischen 40 und 200 kg/m3, bevorzugt 60 und 150 kg/m3, insbesondere bevorzugt zwischen 80 und 120 kg/m3 auf. Die Dicke des vorverdichteten Vlies kann dabei zwischen 20 und 100 mm, bevorzugt 30 und 50 mm, insbesondere bevorzugt 35 und 45 mm liegen.In a further embodiment of the present method, the precompressed nonwoven after leaving the tempering furnace has a bulk density (or a density) between 40 and 200 kg / m 3 , preferably 60 and 150 kg / m 3 , particularly preferably between 80 and 120 kg / m 3 on. The thickness of the pre-compressed nonwoven may be between 20 and 100 mm, preferably 30 and 50 mm, particularly preferably 35 and 45 mm.

Es ist insbesondere bevorzugt, wenn der Vorschub des Förderbandes bzw. Transportbandes im Temperofen in einem Bereich zwischen 5 und 15 m/min, bevorzugt zwischen 6 und 12 m/min liegt.It is particularly preferred if the feed of the conveyor belt or conveyor belt in the annealing furnace in a range between 5 and 15 m / min, preferably between 6 and 12 m / min.

Nach dem Verlassen des Temperofens kann das vorverdichtete Vlies abgekühlt und konfektioniert werden. Typische Konfektionierungsmaßnahmen sind z.B. die Besäumung des Vlieses der dabei anfallende Abfall, insbesondere die anfallenden Randstreifen, können verkleinert werden und in den Verfahrensprozess zurückgeführt werden. Da das gewünschte Mischungsverhältnis gegeben ist, kann das Material direkt in den Faserbunker eingespeist werden.After leaving the annealing furnace, the precompressed nonwoven fabric can be cooled and made up. Typical packaging measures are e.g. the trimming of the web of the resulting waste, in particular the resulting edge strips can be reduced and returned to the process. Since the desired mixing ratio is given, the material can be fed directly into the fiber bunker.

In einer weiteren Variante des vorliegenden Verfahrens wird das vorverdichtete Vlies in der mindestens einen Doppelbandpresse auf eine Dicke zwischen 2 und 20 mm, bevorzugt 4 und 15 mm, insbesondere bevorzugt 5 und 10 mm verdichtet.In a further variant of the present method, the precompressed nonwoven is compressed in the at least one double belt press to a thickness between 2 and 20 mm, preferably 4 and 15 mm, particularly preferably 5 and 10 mm.

Die während des Verdichtens des Vlieses in der mindestens einen Doppelbandpresse angelegte Temperatur ( Öltemperatur im Thermoöl ) liegt zwischen 150 und 250°C, bevorzugt 180 und 230°C, bevorzugt 200 und 220°C. Der in der mindestens einen Doppelbandpresse angewendete Druck kann zwischen 2 MPa und 10 MPa, bevorzugt 3 MPa und 8 MPa, insbesondere bevorzugt 5 und 7 MPa liegen. Der Vorschub der Doppelbandpresse beträgt zwischen 5 und 15 m/min, bevorzugt zwischen 6 und 12 m/min.The temperature applied during the compaction of the fleece in the at least one double-belt press (oil temperature in the thermal oil) is between 150 and 250 ° C., preferably 180 and 230 ° C., preferably 200 and 220 ° C. The pressure applied in the at least one double belt press may be between 2 MPa and 10 MPa, preferably 3 MPa and 8 MPa, particularly preferably 5 and 7 MPa. The feed of the double belt press is between 5 and 15 m / min, preferably between 6 and 12 m / min.

Nach Verlassen der mindestens einen Doppelbandpresse wird die die Doppelbandpresse verlassende verdichtete Holz-Kunststoff-Verbundwerkstoff-Platte in mindestens eine Kühlpresse eingeführt, in welcher ein Abkühlen der verdichteten Holz-Kunststoff-Verbundwerkstoff-Platte auf Temperaturen zwischen 10 und 100°C, bevorzugt 15 und 70°C, insbesondere bevorzugt 20 und 40°C erfolgt. Dabei wird in der mindestens einen Kühlpresse ein Druck angewendet, der identisch oder zumindest fast identisch ist zu dem Druck in der Doppelbandpresse, d.h. in der Kühlpresse herrscht ein Druck zwischen 2 MPa und 10 MPa, bevorzugt 3 MPa und 8 MPa, insbesondere bevorzugt 5 und 7 MPa.After leaving the at least one double belt press, the compacted wood-plastic composite sheet leaving the double belt press is introduced into at least one cooling press, in which cooling of the compacted wood-plastic composite sheet to temperatures between 10 and 100 ° C, preferably 15 and 70 ° C, particularly preferably 20 and 40 ° C. In this case, in the at least one cooling press, a pressure is applied which is identical or at least almost identical to the pressure in the double belt press, i. in the cooling press, a pressure prevails between 2 MPa and 10 MPa, preferably 3 MPa and 8 MPa, particularly preferably 5 and 7 MPa.

Das Einführen der verdichteten Holz-Kunststoff-Verbundwerkstoff-Platte in eine Kühlpresse ist notwendig, da die Rückstellkräfte der Fasern so groß sein können, dass die Platte ohne des Schritts des Kühlpressens nach dem Verdichten in der Doppelbandpresse wieder aufgehen würde.The introduction of the compacted wood-plastic composite plate into a cooling press is necessary because the restoring forces of the fibers can be so great that the plate without the Step of cooling pressing would reappear after compression in the double belt press.

Nach dem Verlassen der Kühlpresse weisen die verdichteten Holz-Kunststoff-Verbundwerkstoff-Platten eine Dicke zwischen 2 und 15 mm, bevorzugt 3 und 12 mm, insbesondere bevorzugt 4 und 10 mm und ganz besonders bevorzugt 4,5 bis 5,5 mm auf.After leaving the cooling press, the compacted wood-plastic composite panels have a thickness between 2 and 15 mm, preferably 3 and 12 mm, more preferably 4 and 10 mm and most preferably 4.5 to 5.5 mm.

Die Rohdichte der verdichteten Holz-Kunststoff-Verbundwerkstoff-Platten nach Verlassen der Kühlpresse liegt in einem Bereich zwischen 500 und 1500 kg/m3, bevorzugt zwischen 650 und 1300 kg/m3, insbesondere bevorzugt zwischen 800 und 1100 kg/m3.The bulk density of the compacted wood-plastic composite panels after leaving the cooling press is in a range between 500 and 1500 kg / m 3 , preferably between 650 and 1300 kg / m 3 , particularly preferably between 800 and 1100 kg / m 3 .

Zur Herstellung einer Holz-Kunststoff-Verbundwerkstoff-Platte mit einer Rohdichte von 850 kg/m3 wird z.B. ein Pressdruck in der Doppelbandpresse (und auch Kühlpresse) von 4,5 bis 5 MPa (45-50 bar) bei einer Presstemperatur in der Doppelbandpresse des Vorlaufes von 235°C und einer Presstemperatur auf der Oberfläche der Platte von 220°C angelegt. Im Falle der Herstellung einer Holz-Kunststoff-Verbundwerkstoff-Platte mit einer Rohdichte von 950 kg/m3 wird ein Pressdruck in der Doppelbandpresse (und auch Kühlpresse) von 5,5 bis 6 MPa (55-60 bar) bei einer Presstemperatur in der Doppelbandpresse des Vorlaufes von 235°C und einer Presstemperatur auf der Oberfläche der Platte von 220°C angelegt.To produce a wood-plastic composite sheet with a density of 850 kg / m 3 , for example, a pressing pressure in the double belt press (and also cooling press) of 4.5 to 5 MPa (45-50 bar) at a press temperature in the double belt press of the flow of 235 ° C and a pressing temperature on the surface of the plate of 220 ° C applied. In the case of producing a wood-plastic composite panel having a bulk density of 950 kg / m 3 , a compacting pressure in the double belt press (and also cooling press) of 5.5 to 6 MPa (55-60 bar) at a press temperature in the Double belt press of the feed of 235 ° C and a pressing temperature on the surface of the plate of 220 ° C created.

Die mit dem vorliegenden Verfahren hergestellten Holzwerkstoffplatten bzw. Holz-Kunststoff-Verbundwerkstoffe (WPC) sind durch eine Quellung von weniger als 5%, bevorzugt weniger als 3%, insbesondere bevorzugt weniger als 1% gekennzeichnet.The wood-based panels or wood-plastic composites (WPC) produced by the present method are characterized by a swelling of less than 5%, preferably less than 3%, particularly preferably less than 1%.

Gemäß einer weiteren Ausgestaltung kann es auch vorgesehen sein, dass die Holzwerkstoffplatte in Form eines WPC zumindest in einem Randbereich der Platte eine Profilierung aufweist, wobei das Profil beispielsweise die Einbringung eines Nut- und/oder Federprofils in eine Kante bzw. Seitenfläche der Holz-Kunststoff-Verbundwerkstoff-Platte ermöglicht, wobei die so erhaltenen Paneele bzw. Holz-Kunststoff-Verbundwerkstoff-Platten miteinander verbunden werden können und eine schwimmende Verlegung und Abdeckung eines Bodens ermöglichen.According to a further embodiment, it can also be provided that the wood-based panel in the form of a WPC has a profiling at least in an edge region of the panel, wherein the profile, for example, the introduction of a tongue and / or groove profile in an edge or side surface of the wood-plastic Composite sheet allows, whereby the thus obtained panels or wood-plastic composite panels can be interconnected and allow a floating laying and covering a floor.

In einer weiteren Ausführungsform des vorliegenden Verfahrens hat es sich als vorteilhaft erwiesen, dem Holzpartikel-Kunststoff-Gemisch vor dem Verdichten weitere Substanzen wie Füllstoffe oder Additive zuzugeben, die der Holz-Kunststoff-Verbundwerkstoff-Platte spezielle Eigenschaften verleihen.In a further embodiment of the present method, it has proved to be advantageous to add further substances, such as fillers or additives, to the wood particle / plastic mixture before compacting, which impart special properties to the wood / plastic composite sheet.

Als geeignete Additive können Flammenschutzmittel, lumineszierende oder antibakterielle Stoffe dem Holzpartikel-Kunststoff-Gemisch zugegeben werden. Geeignete Flammschutzmittel können ausgewählt sein aus der Gruppe enthaltend Phosphate, Borate, insbesondere Ammoniumpolyphosphat, Tris(tri-bromneopentyl)phospat, Zinkborat oder Borsäurekomplexe von mehrwertigen Alkoholen.Flame retardants, luminescent or antibacterial substances may be added to the wood particle / plastic mixture as suitable additives. Suitable flame retardants may be selected from the group comprising phosphates, borates, in particular ammonium polyphosphate, tris (tri-bromneopentyl) phosphate, zinc borate or boric acid complexes of polyhydric alcohols.

Weitere Additive können die UV-Beständigkeit, das Alterungsverhalten oder die elektrische Leitfähigkeit der Holz-Kunststoff-Verbundwerkstoff-Platte beeinflussen. Zur Erhöhung der UV-Beständigkeit ist es z.B. bekannt, Kunststoffen sogenannte UV-stabilisierende Verbindungen wie die sogenannten HALS-Verbindungen zuzusetzen. Als Antifungizide und antibakterielle Mittel können u.a. Polyimine verwendet werden.Other additives may affect the UV resistance, aging behavior or electrical conductivity of the wood-plastic composite panel. To increase the UV resistance it is e.g. known to add plastics so-called UV-stabilizing compounds such as the so-called HALS compounds. As antifungicides and antibacterial agents, i.a. Polyimines are used.

Auch ist es vorteilhaft, dem Holzpartikel-Kunststoff-Gemisch einen anorganischen Füllstoff zuzugeben. Als anorganischer Füllstoff können z.B. Materialien wie Talkum, Kreide, Titandioxid oder andere verwendet werden, die der Platte eine spezifische Färbung verleihen.It is also advantageous to add an inorganic filler to the wood particle-plastic mixture. As the inorganic filler, e.g. Materials such as talc, chalk, titanium dioxide, or others that give the plate a specific color.

Es hat sich überraschenderweise gezeigt, dass sich die so hergestellten Holzwerkstoffplatten auf der Basis von Holz-Kunststoff-Verbundwerkstoffen trotz ihres hohen Kunststoffgehaltes in einer Kurztakt-Presse mit einer Dekorlage versehen und dann zu Laminatboden weiterverarbeiten lassen.It has surprisingly been found that the wood-based panels produced on the basis of wood-plastic composite materials provided in spite of their high plastic content in a short-cycle press with a decorative layer and then can be further processed into laminate floor.

Die Erfindung stellt deshalb ein Verfahren zur Herstellung eines Laminats bereit, umfassend die Schritte

  • Bereitstellen einer großformatigen Platte aus einem Holz-Kunststoff-Verbundwerkstoff mit einer Ober- und einer Unterseite,
  • Aufbringen einer Dekorlage auf wenigstens die Oberseite der großformatigen Platte und
  • Verpressen unter Wirkung von Druck und Temperatur zur Ausbildung eines Laminats.
The invention therefore provides a process for producing a laminate comprising the steps
  • Providing a large-sized plate made of a wood-plastic composite material with a top and a bottom,
  • Applying a decorative layer on at least the top of the large-sized plate and
  • Pressing under pressure and temperature to form a laminate.

Das Aufbringen der Dekorlage auf die Holz-Kunststoff-Verbundwerkstoff-Platten, kann, wie bei einem herkömmlichen Laminat, durch Aufbringen einer Dekorlage auf Zellulosebasis, wie beispielweise durch das Aufbringen von Dekorpapier, erfolgen, wobei der Vielfältigkeit an verschieden gemusterten Dekorpapieren keine Grenzen gesetzt sind. Vorzugsweise werden Dekorpapiere mit einer Imprägnierung, wie beispielsweise einer wärmehärtbaren Kunstharzimprägnierung, für das Herstellen der Dekorlage auf den Holz-Kunststoff-Verbundwerkstoff-Platten verwendet.The application of the decorative layer on the wood-plastic composite panels, as in a conventional laminate, by applying a decorative layer based on cellulose, such as by the application of decorative paper, the variety of differently patterned decorative papers are no limits , Preferably decorative papers with an impregnation, such as a thermosetting Resin impregnation, used for producing the decorative layer on the wood-plastic composite panels.

Weiterhin ist es möglich, auf die Dekorlage noch eine Overlaylage aufzubringen. Die Overlaylage ist vorzugsweise als Zelluloselage ausgeführt, die gefüllt oder nicht gefüllt ist, d. h. mit Teilchen großer Härte ausgerüstet sein kann, um die Abriebfestigkeit zu erhöhen. Vorzugsweise wird bei dem erfindungsgemäßen Verfahren ein Overlaypapier verwendet, das ebenfalls mit einem wärmehärtbaren Kunstharz imprägniert ist. Besonders bevorzugt ist es, wenn die imprägnierten Overlaypapiere zusätzlich mit abriebfesten Partikeln ausgerüstet sind. Die abriebfesten Partikel sind vorzugsweise ausgewählt aus der Gruppe enthaltend Aluminiumoxide, Borcarbide, Siliziumdioxide, Siliziumcarbide und Glaspartikel.Furthermore, it is possible to apply an overlay layer to the decorative layer. The overlay ply is preferably implemented as a cellulosic layer that is filled or unfilled, i. H. can be equipped with particles of high hardness to increase the abrasion resistance. Preferably, in the method according to the invention an overlay paper is used, which is also impregnated with a thermosetting resin. It is particularly preferred if the impregnated overlay papers are additionally provided with abrasion-resistant particles. The abrasion-resistant particles are preferably selected from the group consisting of aluminum oxides, boron carbides, silicon dioxides, silicon carbides and glass particles.

In einer weiteren Ausführungsform des erfindungsgemäßen Verfahrens kann auf die Unterseite der Holz-Kunststoff-Verbundwerkstoff-Platte ein Gegenzug aufgebracht werden. Dadurch werden insbesondere die durch die auf der Oberseite der Holz-Kunststoff-Verbundwerkstoff-Platte aufgebrachten Dekor- und Overlaylagen wirkenden Zugkräfte ausgeglichen. In einer bevorzugten Ausführungsform wird der Gegenzug als Zelluloselage ausgeführt, die imprägniert ist. Beispielsweise kann der Gegenzug als mit einem wärmehärtbaren Kunstharz imprägniertes Papier ausgeführt sein. In einer besonders bevorzugten Ausführungsform entspricht der Schichtaufbau des Gegenzugs dem Schichtaufbau und der jeweiligen Schichtdicke genau der auf der Oberseite aufgebrachten Schichtfolge aus Dekor- und Overlaylagen.In a further embodiment of the method according to the invention, a counter-pull can be applied to the underside of the wood-plastic composite material plate. As a result, in particular the forces acting on the top of the wood-plastic composite sheet applied decor and overlay layers tensile forces are compensated. In a preferred embodiment, the counter-pull is carried out as a cellulose layer which is impregnated. For example, the counter-pull may be embodied as paper impregnated with a thermosetting resin. In a particularly preferred embodiment, the layer structure of the counter-contact corresponds exactly to the layer structure and the respective layer thickness of the layer sequence of decorative and overlay layers applied on the upper side.

Vorzugsweise sind die Dekor-, Overlay und die Gegenzuglage alle als Zelluloselage ausgeführt. Besonders bevorzugt ist es, wenn die Zelluloselagen für die Herstellung der Dekor-, Overlay und der Gegenzuglage mit einem wärmehärtbaren Kunstharz imprägniert sind. Besonders geeignet für die Verwendung in dem erfindungsgemäßen Verfahren sind wärmehärtbare Kunstharze, die für die Herstellung von Laminaten verwendbar sind. Das wärmehärtbare Kunstharz für die Imprägnierung der Zelluloselagen ist deshalb vorzugsweise ausgewählt aus Harnstoffharz, Phenolharz, Melaminharz oder Gemischen daraus.Preferably, the decor, overlay and the Gegenzuglage are all designed as a cellulose layer. It is particularly preferred if the cellulose layers for the production of the decorative, overlay and the counteracting layer are impregnated with a thermosetting synthetic resin. Especially suitable for use in the process according to the invention are thermosetting synthetic resins which are useful for the production of laminates. The thermosetting resin for the impregnation of the cellulose layers is therefore preferably selected from urea resin, phenolic resin, melamine resin or mixtures thereof.

In einer bevorzugten Ausführungsform des erfindungsgemäßen Verfahrens werden die Dekor- und/oder Overlaylagen und der Gegenzug mit der großformatigen Holz-Kunststoff-Verbundwerkstoff-Platte in einem Arbeitsschritt unter Wirkung von Temperatur und Druck in einer Kurztaktpresse verpresst und zu einem Laminat weiterverarbeitet.In a preferred embodiment of the method according to the invention, the decorative and / or overlay layers and the backing with the large-sized wood-plastic composite material plate are pressed in a single step under the action of temperature and pressure in a short-cycle press and processed into a laminate.

Übliche Kurztakt-Pressen arbeiten beispielsweise bei einem Druck von 30 bis 60 kg/cm2, einer Temperatur an der Holzwerkstoffoberfläche von etwa 165 - 175 °C und einer Presszeit von 6 bis 12 Sekunden.Conventional short-cycle presses operate, for example, at a pressure of 30 to 60 kg / cm 2 , a temperature at the wood material surface of about 165 - 175 ° C and a pressing time of 6 to 12 seconds.

Bei Verwendung der Holz-Kunststoff-Verbundwerkstoff-Platten gemäß der Erfindung als Trägermaterialen arbeiten die Kurztaktpressen vorzugsweise bei 30 °C bis 40 °C niedrigeren Temperaturen als bei der Herstellung von Laminaten auf Basis von herkömmlichen Holzfaserplatten. In einer besonders bevorzugten Ausführungsform arbeiten die Kurztaktpressen bei Verwendung der Holz-Kunststoff-Verbundwerkstoff-Platten gemäß der Erfindung bei einer Temperatur von 140°C bis 160°C, an der Plattenoberfläche, ganz besonders bevorzugt bei 150°C an der Plattenoberfläche.When using the wood-plastic composite panels according to the invention as support materials, the short-cycle presses preferably operate at 30 ° C to 40 ° C lower temperatures than in the production of laminates based on conventional wood fiber boards. In a particularly preferred embodiment, when using the wood-plastic composite panels of the invention, the short-cycle presses operate at a temperature of 140 ° C to 160 ° C, at the panel surface, most preferably at 150 ° C at the panel surface.

Die Presszeit der Kurztaktpresse liegt bei Verwendung der Holz-Kunststoff-Verbundwerkstoff-Platten gemäß der Erfindung bei 5 bis 15 s, vorzugsweise bei 7 bis 12 s, besonders bevorzugt bei kleiner oder gleich 10 s, wie beispielsweise 9, 8, 7 oder 6 Sekunden.The pressing time of the short-cycle press is when using the wood-plastic composite plates according to the invention at 5 to 15 s, preferably 7 to 12 s, more preferably less than or equal to 10 s, such as 9, 8, 7 or 6 seconds ,

Wenn bei der Herstellung von Laminaten auf Basis von Holz-Kunststoff-Verbundwerkstoffen Presszeiten größer als 10 s gewählt werden, muss eine Kühlung erfolgen, damit die Struktur der Holz-Kunststoff-Verbundwerkstoff-Platten nicht zerstört wird. Dies kann beispielsweise durch Kühlung der Platten unmittelbar am Auslauf der Presse mittels vorgekühlter Luft erfolgen. Eine weitere Möglichkeit ist das Kühlen mittels gekühlter Walzen oder in einer dafür ausgerüsteten Presse (Kühlzone).If press times greater than 10 s are selected in the manufacture of laminates based on wood-plastic composites, cooling must take place so that the structure of the wood-plastic composite panels is not destroyed. This can be done for example by cooling the plates directly at the outlet of the press by means of pre-cooled air. Another possibility is cooling by means of cooled rolls or in a press equipped for this purpose (cooling zone).

Die herabgesetzte Temperatur und kürzere Presszeit der Kurztaktpresse haben den Vorteil, dass ein unnötiger Wärmeeintrag in die Trägerplatte (Verbundwerkstoff) verhindert und damit eine unerwünschte Plastifizierung und unerwünschte Deformierungen der Trägerplatte vermieden werden können.The reduced temperature and shorter pressing time of the short-cycle press have the advantage that unnecessary heat input into the carrier plate (composite material) is prevented and thus undesirable plasticization and undesirable deformations of the carrier plate can be avoided.

Während der Weiterverarbeitung in der Kurztakt-Presse können unter Verwendung eines strukturierten Pressblechs auch Oberflächenstrukturen in mindestens einer Oberfläche, vorzugsweise mindestens der Oberseite des Trägermaterials wie einer Holz-Kunststoff-Verbundwerkstoff-Platte erzeugt werden, die optional auf das Dekor abgestimmt ausgeführt sein können (so genannte dekorsynchrone Struktur). Vorzugsweise sind die Oberflächenstrukturen weitgehend deckungsgleich zum Dekor ausgebildet. In diesem Fall spricht man von Embossed-In-Register Strukturen Bei Holzdekoren können die Strukturen in Form von Porenstrukturen vorliegen, die der Maserung folgen. Bei Fliesendekoren können die Strukturen Vertiefungen im Bereich von dem Dekor umfasster Fugenfüllungslinien sein.During further processing in the short-cycle press, using a structured press plate, it is also possible to produce surface structures in at least one surface, preferably at least the upper side of the carrier material, such as a wood-plastic composite plate, which optionally can be designed to match the décor called decorsynchronous structure). Preferably, the surface structures are formed largely congruent to the decor. In this case we speak of embossed-in-register structures. In wood decors, the structures in Form of pore structures that follow the grain. For tile decors, the structures may be depressions in the area of joint fill lines enclosed by the decor.

Bei der Beschichtung der Platte müssen allerdings die Presstemperaturen um 30 - 40 °C reduziert werden. Wie das Herabsetzen der Presszeiten unterhalb von 10 Sekunden dient auch diese Maßnahme dazu, einen unnötigen Wärmeeintrag in die Trägerplatte zu verhindern, der zu einer unerwünschten Plastifizierung und damit zu Deformationen führen würde.When coating the plate, however, the pressing temperatures must be reduced by 30 - 40 ° C. Like the reduction of the pressing times below 10 seconds, this measure also serves to prevent an unnecessary introduction of heat into the carrier plate, which would lead to undesired plasticization and thus to deformations.

Wegen des hohen Kunststoffgehaltes besitzt die Holz-Kunststoff-Verbundwerkstoff-Trägerplatte eine deutlich reduzierte Quellung im Vergleich zu Standard-HDF oder auch quellreduzierten HDF. Diese erreichen im beschichteten Zustand bei dem Kantenquelltest gemäß der DIN EN 13329 bei hoher Melaminverstärkung des verwendeten Leims, Kantenquellwerte um ca. 7%. Die erfindungsgemäße Holz-Kunststoff-Verbundwerkstoff-Platte erreicht in beschichtetem Zustand Kantenquellungen von < 4%.Because of the high plastic content, the wood-plastic composite carrier plate has a significantly reduced swelling compared to standard HDF or low-source HDF. These reach in the coated state in the edge swell test according to DIN EN 13329 with high melamine reinforcement of the glue used, edge swell values by about 7%. The wood-plastic composite sheet according to the invention reaches edge swellings of <4% in the coated state.

Die Erfindung stellt weiterhin ein Laminat auf Basis eines Holz-Kunststoff-Verbundwerkstoffs als Träger bereit, das nach dem erfindungsgemäßen Verfahren hergestellt worden ist.The invention further provides a laminate based on a wood-plastic composite as a carrier, which has been prepared by the process according to the invention.

Die vorliegende Erfindung ist in mehrerlei Hinsicht vorteilhaft. Zum Beschichten der Holz-Kunststoff-Verbundwerkstoff-Platten sind die für die Herstellung herkömmlicher Laminate eingesetzten Standardtechnologien mit nur geringfügigen Abweichungen, wie beispielsweise in Bezug auf die Temperatur und Presszeit der Kurztaktpresse, nutzbar. Großformatige Platte können optimal verarbeitet werden. Die beschichteten Holz-Kunststoff-Verbundwerkstoff-Platten weisen im Ergebnis eine sehr niedrige Quellung bei Feuchtigkeitseinwirkung auf.The present invention is advantageous in several respects. For coating the wood-plastic composite panels, the standard technologies used to make conventional laminates can be used with only minor variations, such as temperature and press time of the short-cycle press. Large format plates can be optimally processed. The coated wood-plastic composite panels have, as a result, a very low swelling upon exposure to moisture.

Die mit dem erfindungsgemäßen Verfahren hergestellten Laminate können, in der Möbelindustrie, beispielsweise für Küchen- und Arbeitsplatten oder Restauranttheken verwendet werden, insbesondere aber für Laminatfußböden, Decken- und Wandverkleidungen. Dabei ist der Anwendungsbereich der Holzwerkstoffplatten und Laminate gemäß der Erfindung aufgrund der verbesserten Eigenschaften deutlich breiter als bei herkömmlichen Holzwerkstoffplatten.The laminates produced by the process according to the invention can be used in the furniture industry, for example for kitchen and work surfaces or restaurant counters, but especially for laminate flooring, ceiling and wall coverings. The scope of the wood-based panels and laminates according to the invention, due to the improved properties is significantly wider than in conventional wood-based panels.

Die Erfindung wird nachfolgend anhand von zwei Ausführungsbeispielen näher erläutert.The invention will be explained in more detail with reference to two embodiments.

Ausführungsbeispieleembodiments Beispiel 1: Herstellung von Holz-Kunststoff-Verbundwerkstoff-Platten als TrägerExample 1: Production of wood-plastic composite panels as a carrier

Aus Ballenöffnern wurden Holzfasern (44 Gew.%) und BiCo-Fasern (56 Gew.%, Polyethylenterephtalat/ Polyethylenterephtalat-Coisophtalat) in eine Mischvorrichtung gefördert. Anschließend wurde aus dem Gemisch der Fasern in einer Streuvorrichtung ein Vorvlies gebildet (Flächengewicht: 4.200g/m2), dass auf ein Förderband in einer Breite von 2.800 mm abgelegt wurde. Der Vorschub des Förderbands lag bei ca. 6 m/min.Wood fibers (44% by weight) and BiCo fibers (56% by weight, polyethylene terephthalate / polyethylene terephthalate-coisophthalate) were conveyed from bale openers into a mixing device. Subsequently, a pre-fleece was formed from the mixture of fibers in a scattering device (basis weight: 4,200 g / m 2 ), which was placed on a conveyor belt with a width of 2,800 mm. The feed of the conveyor belt was about 6 m / min.

Das Vorvlies wurde in einem Durchströmungsofen bei Temperaturen von bis zu 160°C auf eine Stärke von 35 mm vorverdichtet. Dabei erreichte das vorverdichtete Vlies eine Kerntemperatur von ca. 130 °C.The fleece was precompressed in a flow-through oven at temperatures of up to 160 ° C to a thickness of 35 mm. The precompressed nonwoven reached a core temperature of approx. 130 ° C.

Direkt nach dem Durchströmungsofen wurde das vorverdichtete Vlies in einer Doppelbandpresse bei einer Produktionsgeschwindigkeit von 6 m/min auf eine Stärke von 5,2 mm verdichtet. Die Öltemperatur im Vorlauf der Doppelbandpresse lag bei 220 °C.Immediately after the throughflow furnace, the precompressed nonwoven was compacted to a thickness of 5.2 mm in a double belt press at a production speed of 6 m / min. The oil temperature in the forerun of the double belt press was 220 ° C.

Hinter der Doppelbandpresse zur Verdichtung schloss sich eine Kühlpresse mit Wasserkühlung an, in der das WPC auf ca. 15 - 40°C abgekühlt wurde. Aus dem Endlosstrang wurden im Anschluss daran Formate geschnitten (2.800 x 1.500 mm).Behind the double belt press for compaction was followed by a cooling press with water cooling, in which the WPC was cooled to about 15-40 ° C. The extruded strand was then cut into formats (2,800 x 1,500 mm).

Die WPC-Formate wurden nach Abkühlung auf der Oberseite mit einer dekorativen Polypropylenfolie für Fussboden-Anwendungen und auf der Rückseite mit einem Gegenzug auf Basis eines geleimten Papiers beklebt. Aus den oben genannten Formaten wurden Fußbodendielen produziert, die an den Seitenflächen mit Verbindungsprofilen nach Art einer Nut und Feder ausgestattet werden. Die so erhaltenen Paneele sind zur Abdeckung eines Bodens geeignet und werden schwimmend verlegt.After cooling, the WPC formats were covered on the top with a decorative polypropylene film for floor applications and on the back with a backing based on a glued paper. From the formats mentioned above floorboards were produced, which are equipped on the side surfaces with connecting profiles in the manner of a tongue and groove. The panels thus obtained are suitable for covering a floor and are laid floating.

Beispiel 2: Laminatherstellung, Dekor aus imprägniertem PapierExample 2: Laminate production, impregnated paper decor

Eine WPC-Platte (5 mm, Rohdichte: 850 kg/m3, Verhältnis Kunststoff zu Holzfasern 56 % zu 44 %) wird in einer Kurztakt-Presse mit einem Aufbau beschichtet, der üblicherweise für einen Laminatboden verwendet wird. Dieser war folgendermaßen:

  • Oberseite
    • Overlay mit Melaminharzimprägnierung (korundgefüllt),
    • Dekorpapier mit Melaminharzimprägnierung
  • Unterseite
    • Gegenzug mit Melaminharzimprägnierung
A WPC plate (5 mm, bulk density: 850 kg / m 3 , ratio of plastic to wood fibers 56% to 44%) is coated in a short-cycle press with a structure that is commonly used for a laminate floor. This one was like this:
  • top
    • Overlay with melamine resin impregnation (corundum filled),
    • Decorative paper with melamine resin impregnation
  • bottom
    • Backing with melamine resin impregnation

Bei den imprägnierten Papieren handelte es sich bezüglich Harzauftrag, VC-Wert (VC-Wert = Gehalt an flüchtigen Bestandteilen) und der Reaktivität um Standardprodukte. Die Beschichtung wurde bei ca. 150°C (Temperatur am Produkt), 40 bar und 9 Sekunden Presszeit ausgeführt. Anschließend wurde die beschichtete Platte abgekühlt und nach einer definierten Lagerzeit an einer Fußbodenstraße zu Dielen mit einem leimlosen Verbindungsprofil aufgetrennt. Aus der Produktion wurden Dielen entnommen und gemäß der DIN EN 13329 einem Kantenquelltest unterworfen. Dabei wurde nach 24 h Prüfdauer eine Kantenquellung von 2,5 % festgestellt. Nach dem Rücktrocknen bei Raumtemperatur ging diese auf 0,5 % zurück.The impregnated papers were standard in terms of resin coverage, VC (volatile matter content) value and reactivity. The coating was carried out at about 150 ° C (temperature on the product), 40 bar and 9 seconds press time. Subsequently, the coated plate was cooled and separated after a defined storage time on a floor road to planks with a glueless connection profile. Planks were removed from production and subjected to an edge swell test in accordance with DIN EN 13329. An edge swelling of 2.5% was determined after 24 hours of testing. After re-drying at room temperature, this went back to 0.5%.

Claims (15)

Verfahren zur Herstellung eines Laminats, umfassend die Schritte • Bereitstellen einer großformatigen Platte aus einem Holz-Kunststoff-Verbundwerkstoff mit einer Ober- und einer Unterseite, • Aufbringen einer Dekorlage auf wenigstens die Oberseite der großformatigen Platte und • Verpressen unter Wirkung von Druck und Temperatur zur Ausbildung eines Laminats. A method of making a laminate comprising the steps Providing a large-sized plate made of a wood-plastic composite material with a top and a bottom, Applying a decorative layer on at least the top of the large-sized plate and • Pressing under pressure and temperature to form a laminate. Verfahren nach Anspruch 1, weiterhin umfassend das Aufbringen einer Overlaylage oberhalb der Dekorlage.The method of claim 1, further comprising applying an overlay layer above the decorative layer. Verfahren nach Anspruch 1 oder 2, weiterhin umfassend das Aufbringen einer Gegenzuglage auf der Unterseite der großformatigen Platte.The method of claim 1 or 2, further comprising applying a Gegenzuglage on the underside of the large-sized plate. Verfahren nach einem der vorherigen Ansprüche, dadurch gekennzeichnet, dass die Dekor-, die Overlay- und die Gegenzuglage als Zelluloselage ausgeführt ist.Method according to one of the preceding claims, characterized in that the decorative, the overlay and the counteracting layer is designed as a cellulose layer. Verfahren nach Anspruch 4, dadurch gekennzeichnet, dass die Zelluloselage mit einem wärmehärtbaren Kunstharz imprägniert ist.A method according to claim 4, characterized in that the cellulose layer is impregnated with a thermosetting resin. Verfahren nach Anspruch 5, dadurch gekennzeichnet, dass das Kunstharz ausgewählt ist aus Harnstoffharz, Phenolharz, Melaminharz oder Gemischen daraus.A method according to claim 5, characterized in that the synthetic resin is selected from urea resin, phenolic resin, melamine resin or mixtures thereof. Verfahren nach einem der Ansprüche 2 bis 6, dadurch gekennzeichnet, dass die Overlaylage mit abriebfesten Partikeln ausgestattet ist.Method according to one of claims 2 to 6, characterized in that the overlay layer is provided with abrasion-resistant particles. Verfahren nach einem der vorherigen Ansprüche, dadurch gekennzeichnet, dass das Verpressen auf einer Kurztaktpresse mittels wenigstens eines strukturierten Pressblechs erfolgt.Method according to one of the preceding claims, characterized in that the pressing takes place on a short-cycle press by means of at least one structured press plate. Verfahren nach Anspruch 9, dadurch gekennzeichnet, dass eine Oberflächenstruktur wenigstens an der Oberseite der großformatigen Platte ausgebildet wird.A method according to claim 9, characterized in that a surface structure is formed at least on the upper side of the large-sized plate. Verfahren nach Anspruch 8 oder 9, dadurch gekennzeichnet, dass die Oberflächenstruktur wenigstens teilweise synchron zu dem Dekor verlaufend ausgebildet ist.A method according to claim 8 or 9, characterized in that the surface structure is formed at least partially extending synchronously to the decor. Verfahren nach einem der vorherigen Ansprüche, dadurch gekennzeichnet, dass die Presstemperatur an der Plattenoberfläche 140 bis 160 °C, vorzugsweise 150 °C beträgt.Method according to one of the preceding claims, characterized in that the pressing temperature at the plate surface 140 to 160 ° C, preferably 150 ° C. Verfahren nach einem der vorherigen Ansprüche, dadurch gekennzeichnet, dass die Presszeit 5 bis 15 s, vorzugsweise 7 bis 12 s, besonders bevorzugt kleiner gleich 10 s ist.Method according to one of the preceding claims, characterized in that the pressing time is 5 to 15 s, preferably 7 to 12 s, more preferably less than or equal to 10 s. Verfahren nach einem der vorherigen Ansprüche, dadurch gekennzeichnet, dass bei Presszeiten größer als 10 s eine Kühlung erfolgt.Method according to one of the preceding claims, characterized in that at pressing times greater than 10 s cooling takes place. Verfahren nach einem der vorherigen Ansprüche, dadurch gekennzeichnet dass die Dicke der großformatigen Platte 4 bis 10 mm, vorzugsweise 4,5 bis 5,5 mm beträgt.Method according to one of the preceding claims, characterized in that the thickness of the large-format plate is 4 to 10 mm, preferably 4.5 to 5.5 mm. Laminat hergestellt nach dem Verfahren nach einem der Ansprüche 1 bis 14.Laminate produced by the process according to one of claims 1 to 14.
EP14198757.8A 2014-11-06 2014-12-18 Method for manufacturing a wood-plastic composite material with decorative layer Active EP3034259B1 (en)

Priority Applications (20)

Application Number Priority Date Filing Date Title
PL14198757T PL3034259T3 (en) 2014-12-18 2014-12-18 Method for manufacturing a wood-plastic composite material with decorative layer
PT141987578T PT3034259T (en) 2014-12-18 2014-12-18 Method for manufacturing a wood-plastic composite material with decorative layer
ES14198757.8T ES2642816T3 (en) 2014-12-18 2014-12-18 Procedure for the manufacture of a wood-plastic composite plate
EP14198757.8A EP3034259B1 (en) 2014-12-18 2014-12-18 Method for manufacturing a wood-plastic composite material with decorative layer
CA2966674A CA2966674C (en) 2014-11-06 2015-05-13 Process for the production of a wood-plastic composite board
ES15726020T ES2817085T3 (en) 2014-11-06 2015-05-13 Board of material derived from wood, in particular in the form of a wood-plastic composite material, and a process for its manufacture
JP2017542277A JP6437128B2 (en) 2014-11-06 2015-05-13 Wood panel, in particular a wood panel in the form of a wood-plastic composite, and a method of manufacturing the wood panel
UAA201705502A UA119483C2 (en) 2014-11-06 2015-05-13 Wooden material panel, in particular in the form of a wood-plastic composite material, and a method for producing the same
EP15726020.9A EP3215327B1 (en) 2014-11-06 2015-05-13 Method for manufacturing a wooden panel, in particular a wood-plastic composite
PCT/EP2015/060622 WO2016071007A1 (en) 2014-11-06 2015-05-13 Wooden material panel, in particular in the form of a wood-plastic composite material, and a method for producing the same
UAA201901546A UA123960C2 (en) 2014-11-06 2015-05-13 PLATE OF WOOD MATERIAL, ESPECIALLY IN THE FORM OF WOOD-PLASTIC COMPOSITE MATERIAL, AND ITS APPLICATION
CN201580060630.0A CN107206620B (en) 2014-11-06 2015-05-13 Wood material plate, in particular in the form of a wood-plastic composite, and method for the production thereof
RU2017119722A RU2667757C1 (en) 2014-11-06 2015-05-13 Plate from wood material, in particular, in type of wood-plastic composite material and method of manufacture thereof
US15/524,457 US10369721B2 (en) 2014-11-06 2015-05-13 Wooden material panel, in particular in the form of a wood-plastic composite material, and a method for producing the same
PL15726020T PL3215327T3 (en) 2014-11-06 2015-05-13 Method for manufacturing a wooden panel, in particular a wood-plastic composite
CN201911219585.5A CN111037700B (en) 2014-11-06 2015-05-13 Floor panel, use of a floor panel and method for producing a panel of natural material
PT157260209T PT3215327T (en) 2014-11-06 2015-05-13 Wooden material panel, in particular in the form of a wood-plastic composite material, and a method for producing the same
RU2018132176A RU2766677C2 (en) 2014-11-06 2018-09-10 Plate made of a wood-based material, containing a wood-plastic composite, and method for manufacture thereof
JP2018212342A JP6817994B2 (en) 2014-11-06 2018-11-12 Wood panels, especially wood panels in the form of wood-plastic composites, and methods of manufacturing the wood panels.
US16/452,031 US11072087B2 (en) 2014-11-06 2019-06-25 Wooden material panel, in particular in the form of a wood-plastic composite material, and a method for producing the same

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP14198757.8A EP3034259B1 (en) 2014-12-18 2014-12-18 Method for manufacturing a wood-plastic composite material with decorative layer

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DE4030774A1 (en) * 1990-09-28 1992-04-02 Dieffenbacher Gmbh Maschf Producing laminar wood type sheet - by gluing sides of continuous core of glued wooden strips, applying fabric to each side and pressing in double band press
EP2030786A2 (en) * 2007-08-28 2009-03-04 Flooring Technologies Ltd. Method for pressing a surface coating of at least one layer onto a wood board
DE102010036454A1 (en) * 2010-07-16 2012-01-19 Fritz Egger Gmbh & Co. Og A method of producing a panel having a decor and a three-dimensional structure
EP2537653A1 (en) * 2011-06-21 2012-12-26 Flooring Technologies Ltd. Method for manufacturing a composite wood board
WO2014111192A1 (en) * 2013-01-18 2014-07-24 Akzenta Paneele + Profile Gmbh Decorative panel having an elastomer powder-modified substrate board
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EP2808463A1 (en) * 2013-05-30 2014-12-03 Flooring Technologies Ltd. Composite wood panel with leather particles or printed layer of leather particles and process for their preparation

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ES2642816T3 (en) 2017-11-20
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PT3034259T (en) 2017-10-11

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