EP4094848B1 - Procede de fabrication d'un stratifie resistant a l'abrasion - Google Patents

Procede de fabrication d'un stratifie resistant a l'abrasion Download PDF

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Publication number
EP4094848B1
EP4094848B1 EP21175734.9A EP21175734A EP4094848B1 EP 4094848 B1 EP4094848 B1 EP 4094848B1 EP 21175734 A EP21175734 A EP 21175734A EP 4094848 B1 EP4094848 B1 EP 4094848B1
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EP
European Patent Office
Prior art keywords
resin
abrasion
wood
layer
resin layer
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EP21175734.9A
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German (de)
English (en)
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EP4094848C0 (fr
EP4094848A1 (fr
Inventor
Patrick Ortlieb
Norbert Kalwa
Björn BURGMANN
Rüdiger KLUPSCH
Georg Seidack
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Flooring Technologies Ltd
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Flooring Technologies Ltd
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Priority to PL21175734.9T priority Critical patent/PL4094848T3/pl
Priority to ES21175734T priority patent/ES2959015T3/es
Priority to EP21175734.9A priority patent/EP4094848B1/fr
Publication of EP4094848A1 publication Critical patent/EP4094848A1/fr
Application granted granted Critical
Publication of EP4094848C0 publication Critical patent/EP4094848C0/fr
Publication of EP4094848B1 publication Critical patent/EP4094848B1/fr
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C5/00—Processes for producing special ornamental bodies
    • B44C5/04—Ornamental plaques, e.g. decorative panels, decorative veneers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D5/00—Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures
    • B05D5/02—Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures to obtain a matt or rough surface
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C5/00—Processes for producing special ornamental bodies
    • B44C5/04—Ornamental plaques, e.g. decorative panels, decorative veneers
    • B44C5/0469—Ornamental plaques, e.g. decorative panels, decorative veneers comprising a decorative sheet and a core formed by one or more resin impregnated sheets of paper
    • B44C5/0476—Ornamental plaques, e.g. decorative panels, decorative veneers comprising a decorative sheet and a core formed by one or more resin impregnated sheets of paper with abrasion resistant properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D2203/00—Other substrates
    • B05D2203/20—Wood or similar material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D2451/00—Type of carrier, type of coating (Multilayers)
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D2601/00—Inorganic fillers
    • B05D2601/20—Inorganic fillers used for non-pigmentation effect

Definitions

  • the present invention relates to a method of making an abrasion resistant laminate.
  • a large number of products or product surfaces that are subject to wear due to mechanical stress must be protected from premature damage or destruction by wear by applying wear-inhibiting layers. These products can be z. B. to furniture, countertops, counters, floors, etc. act. Depending on the frequency and intensity of the stress, different protective measures must be applied so that the user can be guaranteed the longest possible service life.
  • a large number of the products mentioned above have decorative surfaces that quickly become unsightly and/or can no longer be cleaned when they wear out due to intensive use. These decorative surfaces very often consist of paper impregnated with duroplastic resins, which are pressed onto the wood-based material used in so-called short-cycle presses. Melamine-formaldehyde resin is very often used as a duroplastic resin.
  • overlay papers which are thin, ⁇ -cellulose-containing papers, have long been used to protect the decorative surfaces. After impregnation with melamine-formaldehyde resins and co-compression on the decorative paper, these have a high degree of transparency, so that the brilliance of the decor is not or only slightly impaired.
  • overlays with a high proportion of corundum can lead to transparency problems in high service classes in combination with dark decors.
  • the so-called liquid technology is often used today, among other things for reasons of transparency.
  • it does not use impregnated paper, but applies all the layers of a laminate floor to wooden materials in a direct application process using rollers.
  • these are: primer, color primer, print, wear layer.
  • the respective layer can be applied with a single roller or with a plurality of rollers. Multiple jobs are usually used for color priming (for reasons of opacity) and printing (one color) per roller chosen. Of course, the print can also be applied without contact using a digital printer.
  • the wear layer which is intended to minimize the effects of mechanical stress when walking on, essentially consists of melamine resin and corundum particles.
  • a mixture of resin, corundum and auxiliaries (slurry) is either applied to the already printed board with rollers, such as .B. in the EP 1 339 545 B1 described, or the corundum sprinkled into a layer of resin and then covered after intermediate drying of several layers of melamine resin, such as, for example, in the WO2017/198474 A1 described.
  • the structure which also includes a resin backing, is pressed onto the wood-based panel in a short-cycle press at high pressure and high temperature.
  • a chrome-plated, structured steel sheet is used for structuring on the upper side of the press. Since the chrome layer is worn away by contact with the corundum particles, glass beads are added to one or more melamine resin layers after the corundum has been applied.
  • the glass spheres which have a diameter approx. 20 to 30 ⁇ m larger and are less hard than the corundum particles, are intended to act as spacers for the corundum from the metal sheet.
  • the application which is in the order of magnitude of 10 to 15 g/m 2 , is again preferably carried out using a roller system.
  • the order can be made once or several times. This only depends on the number of roller applicators that are behind the corundum application.
  • the invention is therefore based on the technical task of increasing sheet metal service life. This should be done without an increase in costs and also without a general change in production technology.
  • the present process thus enables the provision of a laminate in various formats (i.e. piece goods and not in the form of a continuous web) with high wear resistance in a batch process in a cost-effective manner.
  • a first resin layer in particular in the form of a first duroplastic resin layer, such as a melamine-formaldehyde resin layer, is applied to the decorative layer (pretreated or not pretreated) of the wood-based panel.
  • the first resin layer does not dry or begin to dry, but instead the mixture of abrasion-resistant particles (such as corundum particles and glass beads) is evenly scattered onto the wet or still liquid first resin layer on the upper side of the wood-based panel using a suitable scattering device. Since the first resin layer is still liquid when it is sprinkled on, the abrasion-resistant particles can sink into the resin layer.
  • the abrasion-resistant particles are also well embedded in the resin layer.
  • the procedure described allows scattering of corundum and glass without having to use a second scattering device. Surprisingly, this was possible despite the different size and geometry of the particles. For this purpose, the particles only had to be mixed in a simple mixing device. There was no demixing during further processing (spreading).
  • Flash-off means that a solvent (such as water) in a liquid surface coating slowly evaporates from the surface due to the vapor pressure that the solvent possesses at a certain temperature. Flashing off can be accelerated by a stream of air passed over the surface. This can be done either by the movement of the element on which the surface coating is placed or by an air flow that is passed over the surface coating.
  • the resin layer with the sprinkled mixture of abrasion-resistant particles is not actually dried. It has lost some solvent but still has a high level of stickiness.
  • the abrasion-resistant particles of the mixture are thus fixed in the at least one first resin layer.
  • the abrasion-resistant particles are thus located in a first resin layer which is provided on the decorative layer and which is covered by at least one further, preferably several further resin layers.
  • the mixture of abrasion resistant particles is thus not provided in the outer covering layers (and thus does not protrude from the resin structure), but rather is provided in a lower resin layer.
  • the wear of the press plates can be reduced by covering the abrasion-resistant particles with additional layers of resin.
  • the wood-based panel provided with the decorative layer is not heated in a dryer, such as an IR dryer, before the application of the first resin layer.
  • a dryer such as an IR dryer
  • the first resin layer is applied to a decorative layer provided with a protective layer.
  • This protective layer can be a layer of paper impregnated with a thermosetting resin or a layer of a thermosetting resin, in particular a melamine-formaldehyde resin, urea-formaldehyde resin or melamine-urea-formaldehyde resin and can be glass beads (size 50-150 ⁇ m) included as spacers for intermediate storage of the panels.
  • This protective layer serves as a temporary protection for the decorative layer for storage prior to further processing.
  • the protective layer on the decorative layer is not yet complete cured, but with a certain residual moisture content of about 10%, preferably about 6%, provided and further crosslinkable.
  • Such protective layers are, for example, in the WO 2010/112125 A1 or EP 2 774 770 B1 described.
  • the typically used step of heating decorative layers provided with such a (thermosetting) protective layer serves to heat the protective layer and adjust the degree of residual moisture and the adhesion of subsequent resin layers.
  • the step of heating the protective layer has a negative effect on the scattering pattern of the abrasion-resistant particles. Omitting the heating of the printed wood-based panel provided with a protective layer results in a homogenization of the scatter pattern and thus an even distribution of the abrasion-resistant particles and glass beads on the panel surface.
  • the resin layers to be applied can be in liquid and/or powder form. It is particularly preferred if the first resin layer is applied in liquid form.
  • the further resin layers, which are applied after the mixture of abrasion-resistant particles, can be liquid, powdery or a combination of alternating liquid and powdery resin layers.
  • the resin layers used in the present method are preferably based on thermosetting resins, in particular melamine-formaldehyde resin, urea-formaldehyde resin or melamine-urea-formaldehyde resin.
  • the resins used preferably each contain additives such as hardeners, wetting agents (surfactants or mixtures thereof), defoamers, release agents and/or other components.
  • the wetting agent is used in each of the resin layers in an amount of 0.1-1% by weight.
  • a latent hardener is preferably used as the hardener, such as alkanolamine salts of acids, for example an alkanolamine salt of a sulfonic acid (see DeuroCure from the manufacturer Deurowood).
  • alkanolamine salts of acids for example an alkanolamine salt of a sulfonic acid (see DeuroCure from the manufacturer Deurowood).
  • the proportion of hardener in the individual resin layers varies and can be between 0.5 to 1.5% by weight, preferably 0.7 to 1.3% by weight. It is particularly preferred that the proportion of hardener per application of resin decreases in the production direction; i.e. the proportion of hardener in the lower resin layers is greater than in the upper resin layers. By reducing the amount of hardener from the lower to the upper resin layers, the individual resin layers can be hardened evenly in the KT press.
  • the amount of the first resin layer applied to the upper side of the wood-based panel can be between 50-100 g/m 2 , preferably 60-80 g/m 2 , particularly preferably between 65 and 75 g liquid/m 2 , such as 70 g liquid/m 2 amount to 2 .
  • At least one first resin layer is applied parallel to the upper side and also to the underside of the wood-based panel as a counteract.
  • the amount of the first resin layer applied to the underside of the wood-based panel can be between 50-100 g/m 2 , preferably 60-80 g/m 2 , particularly preferably 70 g/m 2 .
  • the first lower resin layer is preferably colored (eg brownish) in order to simulate a balancing act.
  • the solids content of the resin used for the first resin layer is 60-80% by weight, preferably 65-70% by weight, particularly preferably between 65 and 67% by weight, for both the upper side and the lower side.
  • the first resin layer is preferably applied in parallel or simultaneously to the top and bottom of the wood-based panel in at least one dual application device (roller application unit).
  • the mixture of corundum particles and glass beads is scattered on in a total amount of between 20 and 40 g/m 2 , preferably between 25 and 35 g/m 2 , particularly preferably 30 g/m 2 .
  • corundum particles used are preferably fine corundum (white) with a high level of transparency, so that the optical effect of the underlying decoration is adversely affected as little as possible. Corundum has an uneven three-dimensional shape.
  • the amount of corundum particles in the mixture of abrasion-resistant particles is 5 to 35 g/m 2 , preferably 8 to 30 g/m 2 , particularly preferably 8 to 15 g/m 2 , for example 12 or 18 g/m 2 2 with a mixture quantity of 30 g/m 2 .
  • Corundum particles with a Mohs hardness of at least 9, preferably with cutting edges, and a grain size between 50 and 90 ⁇ m are preferably used.
  • Corundum particles with grain sizes in the classes F180 to F240, preferably F200 can be used.
  • the grain size of class F180 covers a range from 53 - 90 ⁇ m, F220 from 45-75 ⁇ m, F230 34-82 ⁇ m, F240 28-70 ⁇ m (FEPA standard).
  • white aluminum oxide F180 to F240 preferably in a main particle size range of 53-90 ⁇ m, is used as the abrasion-resistant particles.
  • corundum particles of class F200 are used, with F200 being a mixture between F180 and F220 and having a diameter between 53 and 75 ⁇ m.
  • the corundum particles must not be too fine-grained (danger of dust formation, insufficient abrasion resistance), but also not too coarse-grained (protruding from the resin layer). The size of the corundum particles therefore represents a compromise.
  • silanized corundum particles can be used.
  • Typical silanizing agents are aminosilanes.
  • the glass beads used have a Mohs hardness of at least 7 and a diameter of 50 to 150 ⁇ m, preferably 80 to 120 ⁇ m, particularly preferably 90 to 110 ⁇ m.
  • the glass spheres are preferably free of cutting edges and spherical.
  • the amount of scattered glass beads in the mixture of abrasion-resistant particles is between 5 to 35 g/m 2 , preferably 10 to 30 g/m 2 , particularly preferably 15 to 25 g/m 2 , for example 12 or 18 g/m 2 with a mixture quantity of 30 g/m 2 .
  • the glass spheres can (but do not have to) be in silanized form.
  • the embedding of the glass beads in the resin matrix is improved by the silanization of the glass beads.
  • the amount of the additional, second resin layer applied to the upper side and optionally to the underside as a counteract of the wood-based panel can be between 10 and 50 g liquid/m 2 , preferably between 15 and 40 g liquid/m 2 , particularly preferably between 20 and 30 g liquid / m 2 , such as 20 g liquid / m 2 amount.
  • the solids content of the resin used for the second resin layer is 60 and 80% by weight, preferably 65 and 70% by weight, particularly preferably between 65 and 67% by weight for both the upper side and the lower side.
  • further resin layers are applied one after the other to the top and bottom of the wood-based material board in a double application device and dried after each application (e.g. by means of hot air drying).
  • the preferably liquid resin layers applied to the underside of the wood-based material board act as a counteract. Applying the layers of resin to the top and bottom of the wood-based panel in approximately the same amounts ensures that the tensile forces on the wood-based panel caused by the applied layers during pressing cancel each other out.
  • the balancing layer applied to the underside roughly corresponds in terms of layer structure and the respective layer thickness to the layer sequence applied to the top side, but without the addition of abrasion-resistant particles.
  • At least one resin-impregnated paper layer to be applied to the underside of the wood-based panel as a balancing act.
  • the (liquid) resin layers are dried at dryer temperatures of between 150 and 220° C., preferably between 180 and 210° C., in particular in a convection dryer.
  • the temperature is adjusted to the respective resin layers and can vary in the individual convection dryers; for example, the temperature in the second, third and fourth convection dryers may be 205°C and in the fifth and sixth convection dryers 198°C, respectively.
  • convection dryers instead of convection dryers, however, other dryers can also be used.
  • Replacing resin powder with liquid resin eliminates the time-consuming drying process required for liquid overlays, which reduces system costs, exhaust air problems and space requirements. Overall, the present method enables a more flexible technology.
  • the pulverulent resin is applied in an amount of 10 to 50 g/m 2 , preferably 15 to 40 g/m 2 , particularly preferably 20 to 30 g/m 2 .
  • This application quantity of resin powder essentially applies to all resin powder layers to be applied, although these can be adjusted in each case.
  • the scattering density is selected in such a way that covering layers are generated in any case.
  • the particle size of the powdery resin is between 20 and 100 ⁇ m, preferably between 40 and 89 ⁇ m.
  • the powdered resin to be applied (as in the case of the liquid resin) is a duroplastic resin, preferably a urea resin, a melamine resin or a phenolic resin, particularly preferably a melamine-formaldehyde resin. It is preferable if a melamine resin or a urea resin is used for the first resin layer. Only melamine resin is preferably used in the upper layers.
  • “melting” or “gelling” means that the resin layer is not yet fully polymerized, but rather the polymerization is stopped at an intermediate stage in which further crosslinking or polymerization is still possible at a later processing time.
  • the meaning of “gelling” is therefore usually based on the fact that further functional layers are to be applied to the protective layer that has already been applied at a later point in time, or that the product is only to be finished in further processing steps.
  • melamine resin powder can also be added to the melamine resin powder. It is particularly advantageous that because z. B. salting, thickening, settling, hardening influencing effects, etc. poorly compatible with liquid melamine resin substances can be used. These can be salts to increase conductivity, organic or inorganic flame retardants, cellulose derivatives, radical scavengers, pigments, UV absorbers, etc. Accordingly, the powdered resin used can contain additives such as pigments, conductive substances and cellulose.
  • the overall layer thickness of the resin layers applied to the wood-based material board can be between 60 and 200 ⁇ m, preferably between 90 and 150 ⁇ m, particularly preferably between 100 and 120 ⁇ m.
  • the layer structure is pressed under the influence of pressure and temperature in a short-cycle press at temperatures between 150 and 250° C., preferably between 180 and 230° C., particularly preferably at 200° C. and a pressure between 30 and 60 kg/cm 2 , more preferably between 40 and 50 kg/cm 2 .
  • the pressing time is between 5 and 15 seconds, preferably between 7 and 10 seconds.
  • the coated wood-based panel is preferably aligned in the short-cycle press to a structured press plate located in the short-cycle press using markings on the wood-based panel, so that congruence between the decor on the wood-based panel and the structure to be embossed on the press plate is produced. This enables the production of a decor-synchronous structure.
  • the melamine resin layers melt and a laminate is formed by a condensation reaction including the corundum/glass components.
  • the at least one wood-based material panel is a medium-density fiber (MDF), high-density fiber (HDF) or chipboard or coarse particle board (OSB) or plywood panel and/or a wood-plastic panel.
  • MDF medium-density fiber
  • HDF high-density fiber
  • OSB coarse particle board
  • an unpolished wood fiber board in particular MDF or HDF, is used, which is also provided with a pressed skin (rotting layer) on the upper side.
  • Aqueous melamine resin is applied on top to fill the press skin. The melamine resin is later melted in the short-cycle press and thus has a tempering effect in the area of this layer; i.e. it counteracts delamination.
  • the decorative layer already mentioned above can be applied by means of direct printing.
  • direct printing a water-based, pigmented printing ink is applied in gravure or digital printing processes, with the water-based pigmented printing ink being able to be applied in more than one layer, for example in the form of two to ten layers, preferably three to eight layers.
  • the at least one decorative layer is applied, as mentioned, by means of an analog gravure printing and/or a digital printing process.
  • Intaglio printing is a printing technique in which the elements to be imaged are indented in a printing form that is inked before printing.
  • the printing ink is mainly in the indentations and is transferred to the object to be printed, such as a wood fiber board, due to the contact pressure of the printing form and adhesive forces.
  • digital printing on the other hand, the printed image is transferred directly from a computer to a printing machine, such as a laser printer or inkjet printer. This eliminates the use of a static printing form. In both processes, the use of water-based paints and inks or UV-based coloring agents is possible. It is also conceivable to combine the mentioned printing techniques from gravure and digital printing. A suitable combination of printing techniques can be done directly on the carrier plate or the layer to be printed, or before printing by adapting the electronic data records used.
  • the markings required for alignment in the press are also printed together with the decor.
  • At least one primer layer is arranged between the wood material panel or carrier panel and the at least one decorative layer.
  • the primer layer is applied before printing.
  • the primer layer preferably used here comprises a composition of casein or soybean protein as a binder and inorganic pigments, in particular inorganic color pigments.
  • White pigments such as titanium dioxide can be used as color pigments in the primer layer, or other color pigments such as calcium carbonate, barium sulfate or barium carbonate.
  • the primer can also contain water as a solvent. It is also preferred if the pigmented base coat applied consists of at least one, preferably at least two, particularly preferably at least four layers or coats applied in succession, it being possible for the amount applied between the layers or coats to be the same or different.
  • the present method thus makes it possible to produce a laminate from an abrasion-resistant wood material panel provided with a decorative layer and having a resin structure with abrasion-resistant particles, in particular corundum particles and glass beads.
  • the laminate includes at least one wood-based panel, at least one decorative layer on the upper side of the wood-based panel, at least a first resin layer on the upper side and optionally the lower side, at least one layer containing a mixture of abrasion-resistant particles, in particular a mixture of corundum particles and glass beads on and/or in the first resin layer the top of the engineered wood board, and at least a second resin layer on top and optionally on the underside of the engineered wood board.
  • the laminate comprises a wood-based material board provided with a decorative layer with a resin structure consisting of a first resin layer containing abrasion-resistant particles on the upper side, a corresponding resin layer (but without abrasion-resistant particles) on the underside, at least one second resin layer on the upper side and one corresponding resin layer on the underside of the wood-based panel, at least a third resin layer on the upper side and a corresponding resin layer on the underside of the wood-based panel, at least a fourth, fifth and sixth resin layer on the upper side and corresponding resin layers on the underside of the wood-based panel.
  • the present method enables the production of an abrasion-resistant wood-based material board with the following layer structure (seen from bottom to top): Balancing layer made of six resin layers - wood-based material board - primer layer - printed decorative layer - protective layer, in particular a protective layer made of a resin that has not yet fully cured - first resin layer - Layer of abrasion-resistant particles, in particular corundum particles and glass beads (which are preferably partially embedded in the first resin layer) - second resin layer - third resin layer fourth resin layer - fifth resin layer - sixth resin layer.
  • Balancing layer made of six resin layers - wood-based material board - primer layer - printed decorative layer - protective layer, in particular a protective layer made of a resin that has not yet fully cured - first resin layer - Layer of abrasion-resistant particles, in particular corundum particles and glass beads (which are preferably partially embedded in the first resin layer) - second resin layer - third resin layer fourth resin layer - fifth resin layer
  • the protective layer serves to cover the decor and to protect the decor during interim storage (stacking, storage, transport).
  • the other layers of resin on the top form an overlay that protects the finished laminate against abrasion and enables structuring that is synchronized with the decor.
  • no drying device is provided before the first application device, or in the event that a drying device is installed as part of the production line, this drying device is not in operation, i.e. not active.
  • the present production line comprises a total of a simple, one-sided application unit for applying the first resin layer to the top of the printed wood-based panel and five double application units for applying five further resin layers to the top and bottom of the wood-based panel, with at least one drying device for drying behind each double application unit the upper and/or lower resin layer is provided.
  • the scattering device provided in the present production line for the mixture of abrasion-resistant particles, in particular the mixture of corundum particles and glass beads is suitable for spreading powder, granules and includes an oscillating brush system.
  • the spreading device essentially consists of a storage hopper, a rotating, structured roller and a scraper. The amount of abrasion-resistant material applied is determined by the rotational speed of the roller.
  • the spreading device preferably comprises a spiked roller.
  • the at least one scattering device is surrounded or arranged in at least one cabin, which is provided with at least one means for removing dust occurring in the cabin.
  • the means for removing the dust can be designed in the form of a suction device or as a device for blowing in air. Air injection can be achieved via nozzles installed at the plate inlet and outlet, blowing air into the booth. In addition, they can prevent an inhomogeneous scatter curtain of abrasion-resistant material from being created by air movements.
  • the removal of the dust from abrasion-resistant material from the vicinity of the scattering device is advantageous because, in addition to the obvious health hazards for the workers working on the production line, the fine dust from abrasion-resistant particles is also deposited on other parts of the production line and leads to increased wear of the same.
  • the arrangement of the spreading device in a cabin therefore not only serves to reduce the health pollution of dust in the vicinity of the production line, but also prevents premature wear.
  • the scattering device is preferably controlled by a light barrier, the light barrier being arranged in the processing direction in front of the roller (scattering roller) provided below the scattering device. Controlling the scattering device using a light barrier makes sense, since there are more or less large gaps between the individual wood-based panels. This starts the spreading process as soon as a plate is in front of the spreading roller.
  • At least one funnel is provided in front of the scattering roller to collect excess abrasion-resistant particles (i.e. abrasion-resistant particles that are not scattered on the at least one wood-based material board, but rather before the wood-based board is driven in with the help of the transport device under the scattering roller in front of the latter falling down). .
  • the hopper is coupled to at least one conveyor device and a screening device, with the excess material mixture collected in the hopper being transported to the screening device via the conveyor device.
  • the screen mesh of the screening device corresponds to the largest grain of the abrasion-resistant particulate material used (i.e. approx. 80-120 ⁇ m).
  • debris and clumped material such as clumped resin or clumped abrasion resistant material
  • the screened abrasion resistant material can be returned (recycled) to the spreader.
  • the one in the figure 1 The production line shown schematically includes a one-sided application unit 1 (grooved roller) for applying the first layer of resin.
  • a scattering device 20 is provided for evenly scattering the mixture of abrasion-resistant material such as corundum and glass beads onto the first resin layer on the upper side of the HDF panel.
  • Corundum F200 is used as the abrasion-resistant material, which measures around 50-90 ⁇ m in diameter according to the FEPA standard.
  • the glass beads used have a diameter or grain size of 90-110 ⁇ m.
  • the spreading device 20 essentially consists of a storage funnel, a rotating, structured spiked roller and a scraper.
  • the application quantity of the material is determined by the rotational speed of the spreader roller.
  • the mixture falls from the spiked roller at a distance of 5 cm onto the board treated with melamine resin. Since the first resin layer is still liquid when it is sprinkled on, the corundum particles and glass beads can sink into the resin layer.
  • the first layer of resin sprinkled with the mixture of abrasion-resistant particles is flashed off, with the solvent (e.g. water) from the liquid surface coating slowly evaporating out of the surface due to the vapor pressure. Flashing takes place by means of a stream of air that is passed over the surface.
  • solvent e.g. water
  • the board coated with melamine-formaldehyde resin and corundum/glass beads is coated with further melamine-formaldehyde resin (about 20 g/m 2 ).
  • the corundum grains and glass beads are covered with liquid resin or incorporated into the overlay layer. This prevents the removal of the corundum and the glass balls in the convection dryer due to the high level of air turbulence.
  • the assembly of the first and second resin layers is dried in the convection dryer 2a. If a powdered resin is applied instead of a liquid resin, the drying step is omitted.
  • the layer structure is cured in a short-cycle press 7 at a press temperature of 180-220° C. and a press time of 8 to 10 seconds under a specific pressure of 40 kg/cm 2 .
  • the pressed panels are cooled and stored.
  • the one in the figure 2 The production line shown schematically includes the in figure 1 elements shown. Other elements are also planned.
  • the production line includes the figure 2 an IR dryer 1a which is switched off.
  • the IR dryer 1a By switching off the IR dryer 1a from the production line, the electrostatic charging of the panel surface that otherwise takes place in the IR dryer is avoided, which enables the formation of a homogeneous scattering curtain of the corundum.
  • the production line also includes a one-sided application unit 1 (grooved roller) and five double application units 2, 3, 4, 5, 6 for the simultaneous application of the respective resin layer on the top and bottom of the isolated printed material panels, e.g. of printed HDF panels and respectively four convection dryers 2a, 3a, 4a, 5a, 6a arranged behind the application units in the processing direction.
  • a one-sided application unit 1 grooved roller
  • five double application units 2, 3, 4, 5, 6 for the simultaneous application of the respective resin layer on the top and bottom of the isolated printed material panels, e.g. of printed HDF panels and respectively four convection dryers 2a, 3a, 4a, 5a, 6a arranged behind the application units in the processing direction.
  • the scattering device 20 is provided for evenly scattering the mixture of abrasion-resistant material such as corundum and glass beads onto the first resin layer on the upper side of the HDF panel.
  • the first layer of resin sprinkled with the mixture of abrasion-resistant particles is flashed off, with the solvent (e.g. water) from the liquid surface coating slowly evaporating from the surface due to the vapor pressure. Flashing takes place by means of a stream of air that is passed over the surface.
  • solvent e.g. water
  • the assembly of the first and second resin layers is dried in the convection dryer 2a.
  • a third convection dryer 3a for drying the third resin layer is arranged downstream of the third double application unit 3 for applying the third resin layer.
  • the layer structure is pressed in a short-cycle press 7 at a pressing temperature of 180-220 °C and a pressing time of 8 to 10 seconds under a specific pressure of 40 kg/cm 2 .
  • the pressed panels are cooled and stored.
  • liquid melamine resin/m 2 solids content about 65% by weight
  • a melamine resin in the same amount was also applied to the back.
  • Hot air drying followed each application.
  • the structure was then pressed in a short-cycle press at a pressing temperature of 200° C., a pressing pressure of 40 kg/cm 2 and a pressing time of nine seconds.
  • a sample from this production was tested for its behavior under abrasion stress using a Taber abrader in accordance with DIN EN 13329. For comparison, a sample was tested with which 18 g corundum/m 2 had been scattered and 12 g glass beads/m 2 had been applied via slurries in application units two to five. A value of 4500 ⁇ m resulted for the first sample. For the second sample, a value of 4100 ⁇ m.
  • the first variant showed better transparency compared to the second variant. Both variants were pressed on the production line with a new press plate of identical structure until damage to the press plate was observed. These became apparent in the first variant after 12,200 pressings and in variant 2 after 11,000 pressings.
  • an overlay (grammage: 25 g/m 2 ) was impregnated with a melamine resin (solids content: approx. 65% by weight) in a first step in a trough.
  • the melamine resin contained the usual auxiliaries such as hardeners, wetting agents, etc. After passing through the breathing section and squeezing rollers to adjust the resin application (400% based on the paper weight).

Landscapes

  • Laminated Bodies (AREA)

Claims (12)

  1. Procédé pour la fabrication d'un stratifié résistant à l'abrasion comprenant les étapes consistant à :
    - fournir un panneau en matériau dérivé du bois, qui présente sur la face supérieure au moins une couche décorative, en particulier en tant que décor imprimé,
    - appliquer au moins une première couche de résine sur la au moins une couche décorative sur la face supérieure du panneau en matériau dérivé du bois,
    - répandre un mélange composé de particules résistantes à l'abrasion comprenant des particules de corindon et des billes de verre sur la première couche de résine sur la face supérieure du panneau en matériau dérivé du bois ;
    dans lequel la proportion de la quantité de billes de verre répandues dans le mélange composé de particules résistantes à l'abrasion atteint 5 à 35 g/m2,
    - laisser sécher la première couche de résine pourvue du mélange de particules résistantes à l'abrasion sur la face supérieure du panneau en matériau dérivé du bois ;
    - appliquer au moins une autre couche de résine sur la première couche de résine pourvue du mélange de particules résistantes à l'abrasion sur la face supérieure laissée sécher du panneau en matériau dérivé du bois ;
    - compresser la structure de couches avec réalisation d'un stratifié.
  2. Procédé selon la revendication 1, caractérisé en ce que la première couche de résine est appliquée sur une couche décorative pourvue d'une couche de protection.
  3. Procédé selon l'une quelconque des revendications précédentes, caractérisé en ce que les couches de résine à appliquer sont liquides et/ou pulvérulentes.
  4. Procédé selon l'une quelconque des revendications précédentes, caractérisé en ce que les couches de résine sont à base de résine mélamine-formaldéhyde, résine urée-formaldéhyde ou résine mélamine-urée-formaldéhyde.
  5. Procédé selon l'une quelconque des revendications précédentes, caractérisé en ce que le mélange composé de particules de corindon et de billes de verre est répandu dans une quantité totale comprise entre 20 et 40 g/m2, de préférence entre 25 et 35 g/m2, de manière particulièrement préférée de 30 g/m2.
  6. Procédé selon l'une quelconque des revendications précédentes, caractérisé en ce que les particules de corindon présentent une dureté de Mohs d'au moins 9 et une granulométrie comprise entre 50 et 90 µm.
  7. Procédé selon l'une quelconque des revendications précédentes, caractérisé en ce que la proportion de la quantité de particules de corindon dans le mélange composé de particules résistantes à l'abrasion atteint 5 à 35 g/m2, de préférence 10 à 30 g/m2, de manière particulièrement préférée 8 à 15 g/m2.
  8. Procédé selon l'une quelconque des revendications précédentes, caractérisé en ce que les billes de verre présentent une dureté de Mohs d'au moins 7 et un diamètre de 90 à 150 µm, de 90 à 110 µm.
  9. Procédé selon l'une quelconque des revendications précédentes, caractérisé en ce que la proportion de la quantité de billes de verre répandues dans le mélange composé de particules résistantes à l'abrasion atteint 10 à 30 g/m2, de manière particulièrement préférée 15 à 25 g/m2.
  10. Procédé selon l'une quelconque des revendications précédentes, caractérisé en ce qu'au moins une couche de résine est appliquée sur la face inférieure du panneau en matériau dérivé du bois en tant que contre-traction et séchée après application.
  11. Procédé selon l'une quelconque des revendications 1 à 9, caractérisé en ce qu'au moins une couche de papier imprégnée de résine est appliquée sur la face inférieure du panneau en matériau dérivé du bois en tant que contre-traction.
  12. Procédé selon l'une quelconque des revendications précédentes, caractérisé en ce que la compression de la structure de couches sous l'effet d'une pression et d'une température dans la presse à cycle court à des températures comprises entre 150 et 250 °C, de préférence entre 180 et 230 °C, de manière particulièrement préférée à 200 °C et une pression comprise entre 30 et 60 kg/cm2, de manière particulièrement préférée entre 40 et 50 kg/cm2.
EP21175734.9A 2021-05-25 2021-05-25 Procede de fabrication d'un stratifie resistant a l'abrasion Active EP4094848B1 (fr)

Priority Applications (3)

Application Number Priority Date Filing Date Title
PL21175734.9T PL4094848T3 (pl) 2021-05-25 2021-05-25 Sposób produkcji laminatu odpornego na ścieranie
ES21175734T ES2959015T3 (es) 2021-05-25 2021-05-25 Procedimiento para la producción de un material laminado resistente a la abrasión
EP21175734.9A EP4094848B1 (fr) 2021-05-25 2021-05-25 Procede de fabrication d'un stratifie resistant a l'abrasion

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP21175734.9A EP4094848B1 (fr) 2021-05-25 2021-05-25 Procede de fabrication d'un stratifie resistant a l'abrasion

Publications (3)

Publication Number Publication Date
EP4094848A1 EP4094848A1 (fr) 2022-11-30
EP4094848C0 EP4094848C0 (fr) 2023-07-05
EP4094848B1 true EP4094848B1 (fr) 2023-07-05

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EP (1) EP4094848B1 (fr)
ES (1) ES2959015T3 (fr)
PL (1) PL4094848T3 (fr)

Family Cites Families (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE10061497B4 (de) * 2000-12-08 2005-08-11 Treibacher Schleifmittel Gmbh Verschleißschutzschicht auf Basis von Kunstharz, Verfahren zu ihrer Herstellung sowie ihre Verwendung
PT2236313E (pt) 2009-03-31 2012-08-10 Flooring Technologies Ltd Processo para produção de painéis e painel produzido de acordo com o processo
PT2774770E (pt) 2013-03-08 2015-09-14 Flooring Technologies Ltd Processo para a impressão de uma placa de derivado de madeira e placa de derivado de madeira com camada decorativa impressa
PT3246175T (pt) * 2016-05-20 2018-10-22 Flooring Technologies Ltd Processo para a produção de uma placa de derivados de madeira resistente à abrasão e linha de produção para a mesma

Also Published As

Publication number Publication date
ES2959015T3 (es) 2024-02-19
EP4094848C0 (fr) 2023-07-05
EP4094848A1 (fr) 2022-11-30
PL4094848T3 (pl) 2023-12-18

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