EP4379132A1 - Panneaux stratifiés décoratifs pouvant être recouverts - Google Patents

Panneaux stratifiés décoratifs pouvant être recouverts Download PDF

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Publication number
EP4379132A1
EP4379132A1 EP22210882.1A EP22210882A EP4379132A1 EP 4379132 A1 EP4379132 A1 EP 4379132A1 EP 22210882 A EP22210882 A EP 22210882A EP 4379132 A1 EP4379132 A1 EP 4379132A1
Authority
EP
European Patent Office
Prior art keywords
decor paper
decorative
sodium silicate
silicate
clear
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP22210882.1A
Other languages
German (de)
English (en)
Inventor
David Price
Joseph Giansiracusa
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.)
Depco TRH Pty Ltd
Original Assignee
Depco TRH Pty Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Depco TRH Pty Ltd filed Critical Depco TRH Pty Ltd
Priority to EP22210882.1A priority Critical patent/EP4379132A1/fr
Publication of EP4379132A1 publication Critical patent/EP4379132A1/fr
Pending legal-status Critical Current

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Classifications

    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H27/00—Special paper not otherwise provided for, e.g. made by multi-step processes
    • D21H27/18—Paper- or board-based structures for surface covering
    • D21H27/20—Flexible structures being applied by the user, e.g. wallpaper
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H17/00—Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
    • D21H17/03—Non-macromolecular organic compounds
    • D21H17/05—Non-macromolecular organic compounds containing elements other than carbon and hydrogen only
    • D21H17/13—Silicon-containing compounds
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H19/00—Coated paper; Coating material
    • D21H19/02—Metal coatings
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H19/00—Coated paper; Coating material
    • D21H19/66—Coatings characterised by a special visual effect, e.g. patterned, textured
    • 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

Definitions

  • the invention relates to a decorative laminate panel manufactured with a unicolour or printed decor paper as well as a manufacturing process for the laminate panels.
  • Decorative panels based on decor papers are in wide ranging use, being processed to provide a decorative colour or printed decorative surface in many objects, not least in furniture, cabinetry, flooring and wall panelling.
  • a major application is as a low pressure laminate (LPM) whereby the decor paper is saturated with thermosetting amino formaldehyde resin or resins, partially cured (b-stage), and later the b-stage impregnated film is pressed at an elevated temperature between pressplates to provide the decorative surface on a woodpanel such as particleboard or fibreboard, for example medium density fibreboard (MDF) or high density fibreboard (HDF).
  • MDF medium density fibreboard
  • HDF high density fibreboard
  • the decorative surface of the LPM panel based on thermosetting amino formaldehyde resin is inert, resistant to staining and not designed for changes to the surface after the hot pressing step.
  • Woodpanels are an economical and environmentally friendly choice as a substrate for decor papers, where in a positive climate action the wood sequesters CO 2 during the growth of the tree.
  • OSB oriented strand board
  • MDF woodpanel substrates for hot press lamination of amino formaldehyde impregnated decor paper, due in one example to the variations in density across the surface from the inhomogeneous strand structure.
  • NAF 'no added formaldehyde
  • ZAF zero added formaldehyde
  • Particleboard and fibreboard offer a flat uniform surface and the amino resin impregnated decor papers at b-stage allow the resin to flow in a controlled manner into the woodpanel surface and are fully cured in-situ.
  • EP3896043 is the manufacture of a high opacity laminate surface whereby a nonwoven glass fleece is impregnated with a mixture of melamine, cyanuric acid and styrene maleic anhydride amic acid. The impregnation mixture avoids using TiO 2 to provide opacity and does not utilise a formaldehyde based resin.
  • AU2020281056 is directed to painting a mineral silicate material as a coating onto the surface of a substrate or a substrate with an intermediate layer. A build-up of the mineral silicate surface coating may be achieved by painting more than one mineral silicate coating onto the substrate or intermediate layer.
  • decor papers As the manufacture of decor papers is a well-established and economical means to provide colour and or a printed motif, it would be advantageous to make use decor papers in the manufacture of a decorative laminate where there is no hot pressing step, avoiding the use of thermosetting amino formaldehyde resin, and where the choice of substrate could be expanded to include OSB and other materials which may be inhomogeneous or fragile and not suitable for hot pressing b-staged amino formaldehyde impregnated decor paper.
  • the object of the present application is to demonstrate a decorative laminate panel which can be produced without hot pressing.
  • the decorative paper is saturated with a clear or translucent alkali metal silicate and that the surface of the decorative panel is:
  • An objective of the invention is achieved by avoiding the use of thermosetting formaldehyde based saturation resins and no hot pressing, instead the decor paper is saturated with a substantially clear alkali metal silicate solution, preferably a sodium silicate solution.
  • the clear sodium silicate solution saturates the decor paper without affecting the colour or the printed motif. There are no VOCs emanating from the sodium silicate material.
  • the adhesion of the decor paper to the substrate may be done by applying a glue to the substrate and applying the unsaturated decor paper to the glued substrate, alternatively the glue may be applied to both the substrate and to the reverse side of the decor paper and the substrate and decor paper brought together.
  • a light pressure is applied to the decor paper and maintained for a short time to enhance the bonding between the substrate and the decor paper.
  • the decor paper glued to the substrate is saturated with a sodium silicate solution.
  • the application of the sodium silicate solution is by roller coating, spraying or any other appropriate means.
  • Preferably the sodium silicate is not in excess and any excess may be removed by a doctor blade.
  • the decor paper may be saturated with the sodium silicate solution and partially cured before being glued to the substrate material.
  • this saturation step and gluing to a substrate may be an in-line process.
  • the sodium silicate material can be cured by removal of water and or by chemical reaction. Care has to be taken when removing the water so as not to trap water below the surface which may causing blistering. Using NIR electromagnetic radiation enables the quick removal of water without overheating the surface. Chemical reactions with the sodium silicate material reduce surface permeability and increase water resistance, for example by reacting the sodium silicate with a salt of aluminium, magnesium, sodium or zinc oxide or calcium carbonate preferably precipitated calcium carbonate. However, using precipitated calcium carbonate in the sodium silicate solution will have an effect on the colour of the decor paper and or the printed motif.
  • the precipitated calcium carbonate is included as part of the filler during the manufacture of the decor paper and the chemical reaction to cure the sodium silicate takes place when the sodium silicate solution saturates the decor paper.
  • a chemical reaction to cure the sodium silicate provides an improved heat and water resistant surface. Nevertheless, the surface of the sodium saturated decor paper is prone to water damage, or efflorescence, therefore a coating compatible with the sodium silicate and affording a hard wearing characteristic and low permeability of water would be beneficial.
  • Fig.1 depicts the detrimental efflorescence effect shown as a white surface blemish.
  • Mineral silicate paints are compatible with sodium silicate allowing the decor paper saturated with sodium silicate to be painted with a clear mineral silicate paint, for example a clear potassium silicate paint.
  • the mineral silicate paint can be applied to the sodium silicate saturated decor paper before the complete curing of the sodium silicate.
  • Mineral silicate paints are water borne, odourless and contain no VOCs and are non-film forming. According to literature available from CEFIC, soluble silicates have no significant environmental impact and do not possess a chemical oxygen demand (COD) or a biological oxygen demand (BOD). The alkaline nature of sodium silicate and mineral silicate paints provide resistance to microbial attack.
  • COD chemical oxygen demand
  • BOD biological oxygen demand
  • soluble sodium silicates are a colourless inorganic material where the main use has been as a thin film bonding agent for porous substrates such as paper and cardboard processed at high machine speeds where the thin film and fast setting characteristics are advantageous.
  • the SiO 2 to Na 2 O ratio generally varies from 1.6 to 3.3 and the solids content of sodium silicate solution is generally in the 25% to 65% range.
  • the sodium silicate solution may be modified with the addition of small amounts of a surfactant, or a flexibilising agent such as glycerine or other polyhydric alcohols.
  • WO87/02936 nominates a range between 4-10 lbs/1000ft2
  • saturating a decor paper with a sodium silicate solution uses significantly more sodium silicate, without being a limiting example in excess of 200g/m2 of liquid sodium silicate can be achieved with a 200g/m2 decor paper.
  • This volume of sodium silicate enhances the fire resistance of the decorative laminate surface.
  • the substrate for a decorative panel with a sodium silicate saturated decor paper may be chosen from materials such as plasterboard, solid wood panels such as CLT, wood based panels such as plywood, particleboard, fibreboard, or OSB, or a combination of materials, for example a combination of thin MDF and OSB.
  • Other materials such as plastic and metal may also be covered with a sodium silicate saturated decor paper layer and a clear protective layer.
  • an intermediate layer between the decor paper layer and the substrate for example a layer to minimise the show-through of OSB strands, or to cover the edges of the panel.
  • the intermediate layer and or the decorative paper layer may extend further to cover all or part of the edge and or the reverse side of the panel.
  • a decor paper with low ash content and high bulk would be advantageous to avoid uneven expansion and wrinkles occurring, for example a decor paper of 200g/m 2 with about 20% ash content has proven to be less susceptible to uneven expansion and wrinkles in comparison to a 105g/m 2 30% ash decor paper.
  • the decor paper provides a decorative surface having a colour or printed design common to decor papers used for traditional decorative laminates.
  • the basis of this invention is to saturate the decor paper with a metal alkali silicate, preferably a sodium silicate solution.
  • the sodium silicate solution is not pigmented so as not to impact the decorative aspect of the original decor paper.
  • it is standard practise to print the decor paper before impregnation it is also practical to print the decorative surface after the decorative layer has been saturated with sodium silicate and the sodium silicate set or partially cured.
  • the set or partially cured surface of the sodium silicate saturated decor paper may have a primer applied before for printing, preferably inkjet printing.
  • the set or partially cured surface of the sodium silicate saturated decor paper, whether printed or not printed, may be coated with one or more applications of a mineral silicate paint, in which case the mineral silicate paint may contain a photocatalyst, for example Ecosil-ME (Keimtician GmbH, Diedorf Germany).
  • the photocatalyst is in the outermost mineral silicate paint coating.
  • Mineral silicate paint is an inorganic material which does not form a film, therefore the air borne VOCs are able to contact the photocatalyst much more readily than if the photocatalyst is encapsulated in a film forming coating. According to literature to be optimally effective the photocatalyst needs light and air, as well as direct contact with the pollutant ( Effective Cleaning with Light, Feb 1, 2011 Dr Stephan Blöss, Kronos International Inc. ).
  • a clear protective coating may be applied to the mineral silicate paint and in addition to surface protection, the clear protective coating may provide a desired gloss or matte finish.
  • Crommelin ® Diamond Coat Sealer in Gloss or Satin finish proved effective, see Fig.3 .
  • the coating of the sodium silicate saturated decor paper will be with a clear as possible material.
  • the clear protective coating may be used to provide a different effect to the surface, for example Crommelin ® DiamondCoat anti-slip or Chugoku Fluorex (CMP Japan) for weather resistance.
  • the decorative aspect of the decorative panel surface may be created by using a unicolour decor paper, or printed decor paper.
  • the decor paper surface layer should have the capacity to absorb the sodium silicate solution in quantities that enhance fire resistance, for example a 200g/m 2 decor paper with 20% ash content will readily absorb 200g/m 2 of liquid sodium silicate ( ⁇ 40% solids).
  • the weight of the paper and ash content is not limited to 200g/m 2 or 20% ash content.
  • the sodium silicate solution has a tacky aspect, therefore it is preferable to avoid an excess of the sodium silicate solution outside the decor paper, however small excesses can be tolerated and covered by a mineral silicate paint.
  • the mineral silicate paint can be applied before the sodium silicate is completely cured and dry.
  • the decor paper may contain a filler material which will catalyse the sodium silicate solution, for example but not limited to aluminium sulphate, magnesium sulphate or precipitated calcium carbonate.
  • the catalyst filler may comprise 100% of the filler in the decor paper, alternatively the catalyst filler may be one component of the filler material used in the manufacture of the decor paper.
  • a significant process advantage to boost productivity is that before the sodium silicate material has been fully cured it is possible to coat the surface of the sodium silicate saturated decor paper with a mineral silicate paint.
  • the mineral silicate paint is not film forming and allows the evaporation of water from the sodium silicate to complete the curing process. This is described in Example 1.
  • the substantially clear protective coating may include additives to provide properties such as an antimicrobial or antibacterial, furthermore a photocatalyst may be incorporated to destroy VOCs from the surrounding environment when air contacts the decorative panel surface.
  • the photocatalyst can be chosen to perform its function of destroying airborne VOCs by being reactive in sunlight and/or indoor lighting, for example KRONOClean 7000 (Kronos Titan GmbH, Leverkusen Germany).
  • the surface of the decorative panel surface may be smooth or structured.
  • the surface wood strands of an OSB panel may be allowed to telegraph through the decorative surface layer by wetting of the OSB surface, either before or during the adhesion of the decorative layer and or the intermediate layer which creates the opportunity for the wood strands to expand, see Fig.5 .
  • a 200g/m2 decor paper with 20% ash has more bulk than a standard 80g/m2 decor paper and a structured roller can be used to provide a structured surface effect when applied before the sodium silicate saturated decor paper has fully cured.
  • a structured effect may be created in the decor paper during the manufacture of the decor paper.
  • the reverse side of the decorative panel surface may have a sodium silicate saturated decor paper, or may be coated with a substance or material to prevent ingress of water or to provide insulation or another means of fire protection.
  • the edges of the decorative panel may be treated to prevent ingress of moisture, which may be a wax coating, or a surface layer may extend beyond the edge of the panel and be forced on to the edge section, or even extending further to cover part or all of the rear of the panel.

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  • Laminated Bodies (AREA)
EP22210882.1A 2022-12-01 2022-12-01 Panneaux stratifiés décoratifs pouvant être recouverts Pending EP4379132A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
EP22210882.1A EP4379132A1 (fr) 2022-12-01 2022-12-01 Panneaux stratifiés décoratifs pouvant être recouverts

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP22210882.1A EP4379132A1 (fr) 2022-12-01 2022-12-01 Panneaux stratifiés décoratifs pouvant être recouverts

Publications (1)

Publication Number Publication Date
EP4379132A1 true EP4379132A1 (fr) 2024-06-05

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ID=84369781

Family Applications (1)

Application Number Title Priority Date Filing Date
EP22210882.1A Pending EP4379132A1 (fr) 2022-12-01 2022-12-01 Panneaux stratifiés décoratifs pouvant être recouverts

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Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3259536A (en) * 1960-10-01 1966-07-05 Basf Ag Production of fireproofing sheets
GB1364745A (en) * 1971-07-23 1974-08-29 Roehm Gmbh Method of producing paper
WO1987002936A1 (fr) 1985-11-12 1987-05-21 Baird Richard L Produits en carton traites avec un materiau a base de silicate de sodium
EP0314625B1 (fr) 1987-10-30 1990-11-07 Ciba-Geigy Ag Panneau composite pour le revêtement de bâtiments
DE29908316U1 (de) 1999-05-10 1999-08-12 Alsecco Bauchemische Produkte GmbH & Co. KG, 36208 Wildeck Dämmelement oder Dekorplatte für Wände und Decken
WO2013062783A1 (fr) * 2011-10-28 2013-05-02 E. I. Du Pont De Nemours And Company Pigments inorganiques traités possédant un degré de dispersion amélioré et leur utilisation dans les produits à base de papier
US8888904B2 (en) 2012-11-19 2014-11-18 Charley Lee Heat generating graphite sodium silicate coating agent
AU2020281056A1 (en) 2019-12-02 2021-06-17 Depco-Trh Pty Ltd Mineral silicate coating
EP3896043A1 (fr) 2020-04-17 2021-10-20 Depco-Trh Pty Ltd Surface laminée à haute opacité

Patent Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3259536A (en) * 1960-10-01 1966-07-05 Basf Ag Production of fireproofing sheets
GB1364745A (en) * 1971-07-23 1974-08-29 Roehm Gmbh Method of producing paper
WO1987002936A1 (fr) 1985-11-12 1987-05-21 Baird Richard L Produits en carton traites avec un materiau a base de silicate de sodium
EP0314625B1 (fr) 1987-10-30 1990-11-07 Ciba-Geigy Ag Panneau composite pour le revêtement de bâtiments
DE29908316U1 (de) 1999-05-10 1999-08-12 Alsecco Bauchemische Produkte GmbH & Co. KG, 36208 Wildeck Dämmelement oder Dekorplatte für Wände und Decken
WO2013062783A1 (fr) * 2011-10-28 2013-05-02 E. I. Du Pont De Nemours And Company Pigments inorganiques traités possédant un degré de dispersion amélioré et leur utilisation dans les produits à base de papier
US8888904B2 (en) 2012-11-19 2014-11-18 Charley Lee Heat generating graphite sodium silicate coating agent
AU2020281056A1 (en) 2019-12-02 2021-06-17 Depco-Trh Pty Ltd Mineral silicate coating
EP3896043A1 (fr) 2020-04-17 2021-10-20 Depco-Trh Pty Ltd Surface laminée à haute opacité

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