EP3050687A1 - Method for preparation and simultaneous decorative coating of a composite wood board, in particular a wood-plastic composite material - Google Patents

Method for preparation and simultaneous decorative coating of a composite wood board, in particular a wood-plastic composite material Download PDF

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Publication number
EP3050687A1
EP3050687A1 EP15153005.2A EP15153005A EP3050687A1 EP 3050687 A1 EP3050687 A1 EP 3050687A1 EP 15153005 A EP15153005 A EP 15153005A EP 3050687 A1 EP3050687 A1 EP 3050687A1
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EP
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Prior art keywords
wood
plastic
method according
pre
preceding
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Granted
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EP15153005.2A
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German (de)
French (fr)
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EP3050687B1 (en
Inventor
Norbert Dr. Kalwa
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Flooring Technologies Ltd
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Flooring Technologies Ltd
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Priority to EP15153005.2A priority Critical patent/EP3050687B1/en
Priority claimed from CA2966674A external-priority patent/CA2966674A1/en
Publication of EP3050687A1 publication Critical patent/EP3050687A1/en
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B27WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27NMANUFACTURE 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
    • B27N3/00Manufacture of substantially flat articles, e.g. boards, from particles or fibres
    • B27N3/06Making particle boards or fibreboards, with preformed covering layers, the particles or fibres being compressed with the layers to a board in one single pressing operation
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B27WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27NMANUFACTURE 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
    • B27N3/00Manufacture of substantially flat articles, e.g. boards, from particles or fibres
    • B27N3/08Moulding or pressing
    • B27N3/18Auxiliary operations, e.g. preheating, humidifying, cutting-off
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B27WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27NMANUFACTURE 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
    • B27N1/00Pretreatment of moulding material
    • B27N1/006Pretreatment of moulding material for increasing resistance to swelling by humidity
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B27WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27NMANUFACTURE 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
    • B27N3/00Manufacture of substantially flat articles, e.g. boards, from particles or fibres
    • B27N3/08Moulding or pressing
    • B27N3/24Moulding or pressing characterised by using continuously acting presses having endless belts or chains moved within the compression zone
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B27WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27NMANUFACTURE 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
    • B27N7/00After-treatment, e.g. reducing swelling or shrinkage, surfacing; Protecting the edges of boards against access of humidity
    • B27N7/005Coating boards, e.g. with a finishing or decorating layer

Abstract

The present invention relates to a method for producing a wood-based panel, in particular in the form of a wood-plastic composite, comprising the steps of applying a mixture of wood particles (H) and plastic (K) on a first conveyor belt (3) to form a Vorvlieses and Introducing the Vorvlieses in at least one first annealing furnace (4) for precompression; Transferring the precompacted nonwoven fabric into at least one double-belt press (8) with simultaneous application of at least one decorative layer at least to the upper side of the precompacted nonwoven fabric, the further compacting to form a wood-based panel; and cooling the compacted wood-based panel in at least one cooling press (10).

Description

  • The present invention relates to a process for the production and simultaneous decorative coating of a wood-based panel, in particular in the form of a wood-plastic composite material according to claim 1.
  • description
  • The use of wood-based panels, e.g. in the form of wood fiber boards in various configurations for use as a laminate floor or for cladding walls or in the manufacture of furniture has long been known. For example, wood fiber boards in the form of medium density wood fiber boards (MDF boards) or high density wood fiber boards (HDF boards) are used, which are obtained by pressing corresponding 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. Floor laminates based on wood or wood-based materials are often much more problematic.
  • Floor coverings based on wood or wood-based panels such as laminate flooring or 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. In part, inorganic carrier plates are used for the production of products with wooden surfaces, which can lead to gluing, processing or laying problems.
  • As an alternative to the use of laminate flooring with said swelling problem, floor coverings based on polyvinyl chloride (PVC) have been increasingly used in the past, which have very little to no swelling. However, the disadvantage of using PVC floors is their high susceptibility to scratching and creeping, which leads to rapid wear and unsightliness of the floor covering, especially in highly frequented areas (such as sales areas).
  • For these reasons, in the past, so-called wood-plastic composites (WPC) have been used as support materials for wood products. These support materials have a very low swelling of less than 3% and a high dimensional stability.
  • WPCs are composites based on wood flour or wood chips and thermoplastics, to which other additives may be added. The mixtures of wood fibers and thermoplastics are melted and processed into agglomerates. In the further manufacturing process, the agglomerates are melted in extruders and processed into relatively small-sized plates. The width of the plates is usually in a range of less than one meter due to the manufacturing process in an extruder. Also, the productivity per hour is in a low single-digit square meter range, so that the combination of low productivity and limited board size causes relatively high costs of the WPC boards so produced. Usually, the products are only produced in the continuous width in the appropriate widths and separated to the required length.
  • In a newer method ( WO 2014111192 A1 ), the agglomerates are homogeneously scattered on a belt, pressed in a double-belt press to a plate and cooled.
  • The WPC products have a low swelling, can be worked like wood and are very weather-resistant. In the outdoor area, it is usually sufficient if the elements are monochrome (usually brown). This is based on the wood products that are to substitute the WPC products.
  • In recent years, however, has increasingly been thinking about using these WPC panels / - elements indoors. An important area of application is the floor, where there is also a high stability to moisture and water arrives. However, flooring products typically use products with a decorated surface. For this reason, the plain WPC plates or WPC elements must be decorated by the usual methods (painting, printing, foiling, short-cycle coating, etc.).
  • The decorating process, however, faces the problem of relatively small formats. This means that the small format WPC disks can not normally be processed on the existing equipment. Even those, after that in the WO 2014111192 A1 plates produced in the described method are only about one meter wide in size. Thus, the standard format, which is used in the wood-based panel industry (2.07 m width), falls well below.
  • Accordingly, this results in the disadvantages of low productivity, limited plate size and thus expensive method due to necessary additional steps and an additional machine requirements.
  • The present invention is therefore based on the technical object to overcome the disadvantages described and provide a method available that allows for much of a simpler and cheaper production at least for part of the decorating process. It should, if possible, a procedural step can be saved.
  • This object is achieved with a method for producing wood-based panels according to claim 1, in particular by applying at least one decorative layer to at least the surface already during the production of the WPC boards.
  • Accordingly, a method is provided for producing a wood-based panel, in particular in the form of a wood-plastic composite, comprising 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 Vorvlieses in at least one double belt press under simultaneous application of at least one decorative layer at least on the upper side of the Vorvlieses;
    • further compacting the precompacted pre-web into a board of a wood-plastic composite material; and
    • Cooling the compacted panel from the wood-plastic composite material in at least one cooling press.
  • There is thus provided a multi-stage process, in particular a three-stage process in which first of all a mixture of wood particles, e.g. in the form of wood fibers, and plastics, in particular thermoplastics, a Vorvlies or a Dämpfstoffmatte is produced with a low density. This pre-fleece or Dämpfstoffmatte with a low density is then first compressed on a double belt press under high pressure and high temperature and then cooled in a cooling press. The present method enables the production of wood-based panels in the form of large-format wood-plastic composites (WPCs) which are suitable for making backing sheets for use as floor laminates, coupled with high productivity and thus lower costs.
  • 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.
  • 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.
  • As mentioned above, the thermoplastic can be used in the form of plastic fibers. The plastic fibers can be present as monocomponent fibers or as 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. 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 with thermoplastics (such as PVC laminates).
  • 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 a further embodiment of the present method, a wood particle-plastic mixture is used, which has a mixing ratio of wood particles to plastic between 90% by weight of wood particles: 10% by weight of plastics and 20% by weight of wood particles: 80% by weight of plastics, preferably between 70% by weight of wood particles : 30% by weight of plastics and 40% by weight of wood particles: 60% by weight of plastics. The wood particle-plastic mixture used can be exemplified by 44% by weight of wood fibers or wood particles and 56% by weight of Biko fibers, e.g. Polyethylene terephthalate / polyethylene terephthalate coisophthalate fibers or PP / PE fibers.
  • It is also conceivable that the plastic component itself is also a mixture of different plastics. Thus, a plastic mixture of 20 wt.% Bi-component fibers: 80 wt.% PE fibers up to 80 wt.% Bi-component fibers: 20 wt.% 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.
  • The present modified wood particles are to be understood as meaning lignocellulose-containing comminution products such as, for example, wood fibers, wood chips or even wood flour. In the case of using wood fibers in particular dry wood fibers with a length of 1.0 mm to 30 mm, preferably 1.5 mm to 24 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. 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.
  • According to the desired composition of the wood particle-plastic mixture, the individual components (wood particles and plastic) are intimately mixed in a mixer. The mixing of the components can also be done by entering in a blowpipe. Here on the way from the addition of the components to the reservoir intensive mixing by the injected air as a means of transport. The intensive mixing of the components is continued in the reservoir by the blown in transport air.
  • From the reservoir, the wood particle-plastic mixture, for example, after weighing on a scale, uniformly inflated on a first conveyor belt over its width. The amount of supplied wood particle-plastic mixture depends on the desired layer thickness and the desired bulk 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.
  • After applying the wood particle-plastic mixture on a first conveyor belt to form a Vorvlieses, the Vorvlies is introduced 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.
  • 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 connection between the plastic material, for example the plastic fibers, with the wood fibers is produced and, at the same time, compaction of the pre-fleece takes place. The higher the core temperature of the pre-fleece is the faster the press can be driven, since the compression process is accelerated.
  • The temperatures in the annealing furnace are obtained, for example, by injected hot air.
  • In a further embodiment of the present method, the precompressed pre-fleece, after leaving the tempering furnace, has a bulk density (or density) between 40 and 200 kg / m 3 , preferably 60 and 150 kg / m 3 , particularly preferably between 80 and 120 kg / m 3 up. The thickness of the pre-compressed pre-fleece can be between 20 and 100 mm, preferably 30 and 50 mm, particularly preferably 35 and 45 mm.
  • 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.
  • After leaving the tempering furnace, the precompacted fleece can be cooled down and made up. Typical packaging measures are e.g. the trimming of the fleece. 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 reservoir.
  • In a further variant of the present method, the precompressed pre-fleece in the at least one double-belt press is compacted to a thickness between 2 and 20 mm, preferably 3 and 15 mm, particularly preferably 4 and 10 mm.
  • In a preferred variant of the present method, a decorative layer is applied simultaneously in this at least one double-belt press at least on the upper side of the pre-compacted pre-fleece during this compacting process. This can be done in a simple manner by feeding the decorative layer to the at least one double belt press by means of an unwinding device.
  • The application of the decorative layer on the pre-compressed Vorvlies can, 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 Decor papers with an impregnation, such as a thermosetting resin impregnation or a radiation-curable varnish, used for producing the decorative layer on the wood-plastic composite panels.
  • In a further variant of the method according to the invention, the decorative layer can be applied to the pre-compressed pre-fleece by applying at least one plastic, finish and / or primer film. It is also possible to apply a plurality of films, for example 2, 3, 4 or 5 films, selected from the plastic, finish and / or primer films. It is particularly preferred if a decorative finish film is used to apply the decorative layer.
  • Furthermore, it is possible to provide at least the upper side of the panel of the wood-plastic composite material with a surface structure, for example using structural sensors, wherein the pattern generator can also perform the protective function in addition to the structuring.
  • The formation of the surface structure at least on the upper side of the plate of the wood-plastic composite material can be carried out in particular by:
  1. a) use of an already structured decorative film;
  2. b) using a texturing paper carried between the upper belt of the double belt press and the top of the pre-compacted pre-web; or
  3. c) embossing of a structure during the passage through the double belt press by using an upper belt of the double belt press, which in turn has a structure.
  • The structured decorative film according to option a) can be, for example, a plastic film, which in turn is already structured.
  • Furthermore, the method according to the invention may comprise the simultaneous application of an overlay layer above the decorative layer during the transfer of the precompacted pre-fleece into the double belt press. In a subsequent structuring, such as when using a structured donor paper or a structured upper band in the double belt press, this overlay layer can be structured accordingly.
  • In the case of the possibility a) described above, no subsequent structuring of the overlay layer is necessary any more since the decorative layer is already structured.
  • The overlay layer may be filled or unfilled, ie. H. 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 or a radiation-curable lacquer. 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 another embodiment of the method according to the invention, a plastic film, for example a PP film, can also be used as the overlay layer.
  • 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.
  • Preferably, the decor, overlay and the Gegenzuglage are all designed as a cellulose layer. It is particularly preferred if the cellulose layers are impregnated with a thermosetting synthetic resin or or radiation-curable lacquer for the production of the decorative, overlay and the counter-tension layer.
  • 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 radiation-curable lacquer is typically a non-water-compatible lacquer, e.g. selected from the group of acrylates, modified acrylates and / or epoxides.
  • In a further variant of the method according to the invention, release papers or release films can be used at least on the upper side in order to avoid adhesions or thermal overloading of the decorative layer with or through the metal bands of the double belt press.
  • Particularly good results in the simultaneous application of the decorative layer and possibly the Gegenzuglage on the pre-compressed pre-web and the further compression of the pre-densified Vorvlieses in at least one Dopelbandpresse can be achieved if in the plastic fiber portion of the wood-plastic composite, the proportion of PE or PP fibers at least 40% by weight, for example 45% by weight, 50% by weight, 55% by weight, 60% by weight or higher. The other plastics can z. B. from low-melting BiCo fibers (see above). A preferred blend of plastic fibers may consist of 60 wt% Bi component fibers: 40 wt% PE or PP fibers up to 40 wt% bicomponent fibers: 60 wt% PE or PP fibers.
  • When compacting the nonwoven fabric in the double belt press, work is preferably carried out in a temperature window in which the plastic component in the nonwoven is at least plasticized into the core, but the thermal stability of the decorative layer used, such as a film, is not exceeded. Thus, a direct bonding of the decorative layer with the molten or at least plasticized plastic component in Vorvlies is achieved in the manufacturing process. In this case, either a symmetrical heating of Vorvlieses done with the decorative layer by the two circumferential metal bands of the double belt press or an asymmetrical heating from the bottom to minimize the thermal stress on the decorative layer. The temperature applied during the compaction of the nonwoven fabric in the at least one double-belt press is between 150 and 250 ° C., for example at 160 ° C., preferably between 180 and 230 ° C. or 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.
  • After leaving the at least one double belt press, the compacted wood material board leaving the double belt press is introduced into at least one cooling press, in which cooling the compacted wood-based panel to temperatures between 10 and 100 ° C, preferably 15 and 70 ° C, particularly preferably 20 and 40 ° C. In this case, a pressure is used in the at least one cooling press, which is identical or at least almost identical to the pressure in the double belt press, ie in the cooling press prevails a pressure between 2 MPa and 10 MPa, preferably 3 MPa and 8 MPa, more preferably 5 and 7 MPa.
  • The introduction of the compacted wood-based panel into a cooling press is necessary because the restoring forces of the fibers may be so great that the panel would rise again without the step of cooling pressing after the compacting in the double belt press.
  • After leaving the cooling press, the compacted wood-based panels have a thickness between 2 and 15 mm, preferably 3 and 12 mm, particularly preferably 4 and 10 mm.
  • The bulk density of the compacted wood-based 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 .
  • To produce a wood-based panel with a bulk density of 850 kg / m 3 , for example, advantageously a compacting 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 the production of a wood-based panel with a density of 950 kg / m 3 is advantageously 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 flow of 235 ° C and a pressing temperature on the surface of the plate of 220 ° C applied.
  • 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%.
  • Following the production of the wood-based panels in the format of WPCs, a direct further processing of the panels to suitable decorative panels or floor coverings can preferably take place.
  • According to a further embodiment, it may also be provided that the wood-based material panel in the form of a WPC has a profiling at least in an edge region of the panel, the profile enabling, for example, the introduction of a tongue and / or groove profile into an edge or side surface of the wood-based panel, wherein the panels or wood-based panels obtained in this way can be connected to one another and allow a floating installation and covering of a floor.
  • 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-based material board.
  • 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.
  • Other additives can influence the UV resistance, the aging behavior or the electrical conductivity of the wood-based 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.
  • 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.
  • The invention will be explained in more detail with reference to the figure of the drawing of an embodiment. It shows:
  • FIG. 1
    a schematic representation of an embodiment of the method according to the invention.
  • This in FIG. 1 Process diagram shown comprises a mixing device 1, in which wood fibers H and plastic K, eg Biko fibers are introduced. The mixing device 1 may be in the form of a blowpipe, for example, in which an intensive mixing of the wood fibers and biko fibers is effected by the injected air.
  • From the mixing device 1, the fiber mixture passes into a spreader 2, from which the fiber mixture is mechanically discharged and is scattered onto a conveyor belt 3 to form a preliminary web. The spreader 2 may e.g. be formed in the form of a roller litter. Below the conveyor belt, a scale may e.g. be arranged in the form of a belt scale, which continuously determines the weight of Vorvlieses.
  • The conveyor belt 3 leads the pre-fleece into a tempering oven 4, e.g. in the form of a flow-through furnace with a feed rate of up to 15 m / min. In the annealing oven at temperatures of up to 200 ° C, a pre-compaction of Vorvlieses, wherein the Biko fibers are melted and a connection of the Biko fibers is effected with the wood fibers. The thickness of the pre-batt leaving the tempering furnace can be between 20 and 100 mm.
  • After leaving the tempering furnace 4, the precompacted fleece is introduced directly into a double belt press 8 with a feed rate of up to 12 m / min. At the same time, by means of the unwinding device 5, a decorative finish foil is applied to the upper side of the pre-fleece and, by means of the unwinding device 7, a back-pull paper is applied to the underside of the pre-fleece. Optionally, after applying the decorated paper with the unwinding device 5, a release paper or release film can be applied to the unwinding device 6. In the double belt press 8 further densification of the web or pre-fleece takes place at a pressure of e.g. 3 MPa and a temperature of e.g. 160 ° to a thickness between 2 and 15 mm, for example to 4.5 mm.
  • After the melting of the Biko fibers, the compression state of the double belt press 8 leaving plate must be kept constant until the Biko fibers have cooled down so far that the softening temperature of the same is certainly below, to a "rising" of the compacted plate due to to prevent the restoring forces of the biko fibers. For this purpose, the compacted plate leaving the double belt press 8 is introduced directly into a cooling press 10 in which cooling of the compacted plate takes place at temperatures between 15 and 40 ° C. The cooling of the cooling press can be done eg by means of water cooling. When leaving the double belt press 8, the optionally applied release paper or the release film is removed again by means of the take-up device 9.
  • After leaving the cooling press 10, the compacted (WPC) plate has a thickness of between 2 and 12 mm and a bulk density of, for example, 800 to 1100 kg / m 3 . The WPC plate can then be further processed and assembled as desired.
  • The method according to the invention differs from the conventional production methods for decorated floor, ceiling or wall panels, such as e.g. Laminates, characterized in that the order of the decorative layer, optionally the Overlaylage and the Gegenzuglage already much earlier in the production process, namely simultaneously in the process step of densification of Vorvlieses to a support plate, in this case the compression of the Vorvlieses to a WPC plate is performed ,
  • In contrast, in conventional methods, first the complete production of the carrier plates. These carrier plates are then processed directly or optionally only after an intermediate storage. It is only during further processing that the application of the decoration, the application of protective layers and optionally also a counter-tensioning layer take place. In a further separate step, the pressing of this layer structure into a laminate and, optionally, the structuring of the decorated surface in a short-cycle press must take place. However, the decor and overlay layers and the Gegenzuglage can not be easily applied to the carrier plate without further pretreatment. At least one grinding of the surfaces of the carrier plate is necessary. To fix the decorative and overlay layers and the Gegenzuglage the use of adhesives is necessary.
  • Compared to this conventional method, the method according to the present invention has numerous advantages. The process steps "pre-treatment of the carrier plate by grinding" and the very energy-consuming pressing of the layer structure to a laminate in a short-cycle press can be omitted. As a result, the production process of decorated carrier plates can be greatly simplified. This leads to high energy and cost savings. Further savings are that no use of adhesives for fixing the decorative and overlay layers and the counter-pull is more necessary.
  • Compared to this conventional method, the method according to the present invention has numerous advantages. The process steps "pre-treatment of the carrier plate by grinding" and the very energy-consuming pressing of the layer structure to a laminate in a short-cycle press can be omitted. As a result, the production process of decorated carrier plates can be greatly simplified. This leads to high energy and cost savings.
  • embodiment
  • Fiber cake blanks consisting of 54% by weight of plastic fibers (27% by weight of PE fibers and 27% by weight of PET bico fibers), 44% by weight of wood and 2% by weight of paraffin having a weight per unit area of 3150 g / m 2 Thickness of 35 mm and a format of 1300 x 1400 mm were placed on a conveyor belt before a double belt press. The double belt press had a heating zone with a length of three meters and a cooling zone with a length of six meters.
  • From above, a decorative finish film was applied to the fiber cake via an unwinding device, which was coated on top with a corundum-containing, radiation-curing lacquer. The weight of the coated paper was about 200 g / m 2 . With a second unwinding a release paper was applied to the decorative film. On the underside of the fiber cake a Gegenzugpapier (grammage: 80 g / m 2 ) was fed via an unwinding device.
  • The fiber cake then entered the double belt press and was compressed to a thickness of 4.5 mm at a feed rate of 2 m / min., A pressure of 30 bar and a temperature at the upper and lower steel strip of 160 ° C. With a running thermocouple, the temperature was determined in the fiber cake center. It was 140 ° C at the end of the heating zone.
  • Behind the press, the release paper was wound up. The decorative paper and the Gegenzugpapier were homogeneous and wrinkle-free on the resulting during the pressing process WPC plate (WPC = wood plastic composite, wood-plastic composite) has been pressed. In the cross-cut test, the decorative paper could only be peeled off with a full-surface fiber backing on the back, which suggests a very good bond between the film and the WPC plate.
  • Claims (15)

    1. Process for producing a wood-based panel, in particular in the form of a wood-plastic composite, comprising the 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 Vorvlieses in at least one double belt press with simultaneous application of at least one decorative layer at least on the upper side of the Vorvlieses;
      - further compacting the precompacted pre-web into a board made of a wood-plastic composite material; and
      - Cooling the compacted plate made of wood-plastic composite material in at least one cooling press.
    2. The method of claim 1, further comprising simultaneously applying an overlay ply above the decor ply during transfer of the precompressed pre-batt into the at least one double belt press.
    3. The method of claim 1 or 2, further comprising the simultaneous application of a release liner above the decorative layer and / or overlay during transfer of the pre-densified Vorvlieses in the at least one double belt press.
    4. Method according to one of the preceding claims, further comprising the simultaneous application of a Gegenzuglage on the underside of the precompacted Vorvlieses during the transfer into the at least one double belt press.
    5. Method according to one of the preceding claims, characterized in that the decorative layer is selected from the group consisting of plastic films, finish foils, Grundierfolien and decorative papers based on cellulose.
    6. Method according to one of the preceding claims, characterized in that the decorative layer and / or the Gegenzuglage are impregnated with a thermosetting resin or a radiation-curable lacquer.
    7. Method according to one of the preceding claims, further comprising the formation of a surface structure at least at the top of the plate made of the wood-plastic composite material, in particular by:
      a) use of an already structured decorative film;
      b) using a texturing paper carried between the upper belt of the double belt press and the top of the pre-compacted pre-web; or
      c) embossing of a structure during the passage through the double belt press by using an upper belt of the double belt press, which in turn has a structure.
    8. A method according to claim 7, characterized in that the structured according to a) decorative film is an already structured plastic film.
    9. Method according to one of the preceding claims, characterized in that a mixture of polyethylene (PE) - or polypropylene (PP) - and bicomponent fibers is used as the plastic.
    10. Method according to one of the preceding claims, characterized in that the wood particle-plastic mixture has a mixing ratio of 90% by weight of wood particles / 10% by weight of plastic and 20% by weight of wood particles / 80% by weight of plastic, preferably between 70% by weight of wood particles / 30% by weight Plastic and 40% by weight of wood particles / 60% by weight of plastic.
    11. Method according to one of the preceding claims, characterized in that in the plastic fiber portion of the wood-plastic composite material, the proportion of PE or PP fibers at least 40 wt.% Is.
    12. Method according to one of the preceding claims, characterized in that the precompressed pre-fleece is cooled and made ready after leaving the tempering furnace.
    13. Method according to one of the preceding claims, characterized in that the precompressed pre-fleece in the at least one double belt press to a thickness between 2 and 20 mm, preferably 3 and 15 mm, particularly preferably 4 and 10 mm is compressed.
    14. Method according to one of the preceding claims, characterized in that the precompressed pre-fleece in the at least one double belt press at temperatures between 150 and 250 ° C and / or at a pressure between 2 MPa and 10 MPa, preferably 3 MPa and 8 MPa is compressed.
    15. Method according to one of the preceding claims, characterized in that the compressed plates of the wood-plastic composite material after leaving the cooling press have a thickness between 2 and 15 mm, preferably 3 and 12 mm, particularly preferably 4 and 10 mm.
    EP15153005.2A 2015-01-29 2015-01-29 Method for preparation and simultaneous decorative coating of a composite wood board, in particular a wood-plastic composite material Active EP3050687B1 (en)

    Priority Applications (1)

    Application Number Priority Date Filing Date Title
    EP15153005.2A EP3050687B1 (en) 2015-01-29 2015-01-29 Method for preparation and simultaneous decorative coating of a composite wood board, in particular a wood-plastic composite material

    Applications Claiming Priority (13)

    Application Number Priority Date Filing Date Title
    ES15153005.2T ES2630181T3 (en) 2015-01-29 2015-01-29 Procedure for the manufacture and simultaneous decorative coating of a board of wood-derived material, especially a composite material of wood and plastic
    PL15153005T PL3050687T3 (en) 2015-01-29 2015-01-29 Method for preparation and simultaneous decorative coating of a composite wood board, in particular a wood-plastic composite material
    EP15153005.2A EP3050687B1 (en) 2015-01-29 2015-01-29 Method for preparation and simultaneous decorative coating of a composite wood board, in particular a wood-plastic composite material
    CA2966674A CA2966674A1 (en) 2014-11-06 2015-05-13 Process for the production of a wood-plastic composite board
    EP15726020.9A EP3215327A1 (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
    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
    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
    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
    RU2018132176A RU2018132176A (en) 2014-11-06 2015-05-13 Wood-based plate containing a wood-plastic composite and method for producing it
    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
    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
    JP2018212342A JP2019038267A (en) 2014-11-06 2018-11-12 Woody material panel, in particular, woody material panel in the form of wood-plastic composite material, and method of producing woody material panel
    US16/452,031 US20190315015A1 (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

    Publications (2)

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    EP3050687A1 true EP3050687A1 (en) 2016-08-03
    EP3050687B1 EP3050687B1 (en) 2017-04-12

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    EP (1) EP3050687B1 (en)
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    Citations (6)

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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
    US20040028958A1 (en) * 2002-06-18 2004-02-12 Total Innovative Manufacturing Llc Recyclable fire-resistant moldable batt and panels formed therefrom
    WO2009135883A1 (en) * 2008-05-06 2009-11-12 Fritz Egger Gmbh & Co. Derived timber plate provided with a high-gloss laminate coating, and method for producing such a derived timber plate
    WO2014111192A1 (en) 2013-01-18 2014-07-24 Akzenta Paneele + Profile Gmbh Decorative panel having an elastomer powder-modified substrate board
    EP2762328A1 (en) * 2013-01-30 2014-08-06 Flooring Technologies Ltd. Method for producing a decorated wooden board coated on both sides
    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

    Patent Citations (6)

    * Cited by examiner, † Cited by third party
    Publication number Priority date Publication date Assignee Title
    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
    US20040028958A1 (en) * 2002-06-18 2004-02-12 Total Innovative Manufacturing Llc Recyclable fire-resistant moldable batt and panels formed therefrom
    WO2009135883A1 (en) * 2008-05-06 2009-11-12 Fritz Egger Gmbh & Co. Derived timber plate provided with a high-gloss laminate coating, and method for producing such a derived timber plate
    WO2014111192A1 (en) 2013-01-18 2014-07-24 Akzenta Paneele + Profile Gmbh Decorative panel having an elastomer powder-modified substrate board
    EP2762328A1 (en) * 2013-01-30 2014-08-06 Flooring Technologies Ltd. Method for producing a decorated wooden board coated on both sides
    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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    EP3050687B1 (en) 2017-04-12
    PL3050687T3 (en) 2017-09-29
    ES2630181T3 (en) 2017-08-18

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