RU2344940C2 - Method of manufacturing structural boards such as floor panels and furniture boards and board proper - Google Patents

Method of manufacturing structural boards such as floor panels and furniture boards and board proper Download PDF

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Publication number
RU2344940C2
RU2344940C2 RU2007103011/12A RU2007103011A RU2344940C2 RU 2344940 C2 RU2344940 C2 RU 2344940C2 RU 2007103011/12 A RU2007103011/12 A RU 2007103011/12A RU 2007103011 A RU2007103011 A RU 2007103011A RU 2344940 C2 RU2344940 C2 RU 2344940C2
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Russia
Prior art keywords
surface
method according
layer
plate
synthetic resin
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RU2007103011/12A
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Russian (ru)
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RU2007103011A (en
Inventor
Раймунд ХАГШПИЛЬ (DE)
Раймунд ХАГШПИЛЬ
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Фриц Эггер Гмбх Унд Ко.
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Priority to DE102004032058A priority Critical patent/DE102004032058B4/en
Priority to DE102004032058.6 priority
Application filed by Фриц Эггер Гмбх Унд Ко. filed Critical Фриц Эггер Гмбх Унд Ко.
Publication of RU2007103011A publication Critical patent/RU2007103011A/en
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Publication of RU2344940C2 publication Critical patent/RU2344940C2/en

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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B41PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41MPRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING
    • B41M5/00Duplicating or marking methods; Sheet materials for use therein
    • B41M5/50Recording sheets characterised by the coating used to improve ink, dye or pigment receptivity, e.g. for ink-jet or thermal dye transfer recording
    • B41M5/52Macromolecular coatings
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B41PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41MPRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING
    • B41M1/00Inking and printing with a printer's forme
    • B41M1/26Printing on other surfaces than ordinary paper
    • B41M1/38Printing on other surfaces than ordinary paper on wooden surfaces, leather, or linoleum
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B44DECORATIVE ARTS
    • B44CPRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C5/00Processes for producing special ornamental bodies
    • B44C5/04Ornamental plaques, e.g. decorative panels, decorative veneers
    • B44C5/043Ornamental plaques, e.g. decorative panels, decorative veneers containing wooden elements
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00Flooring
    • E04F15/02Flooring or floor layers composed of a number of similar elements
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B05SPRAYING OR ATOMISING IN GENERAL; APPLYING LIQUIDS OR OTHER FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05DPROCESSES FOR APPLYING LIQUIDS OR OTHER FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D2203/00Other substrates
    • B05D2203/20Wood or similar material
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B05SPRAYING OR ATOMISING IN GENERAL; APPLYING LIQUIDS OR OTHER FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05DPROCESSES FOR APPLYING LIQUIDS OR OTHER FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D5/00Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures
    • B05D5/06Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures to obtain multicolour or other optical effects
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B41PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41MPRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING
    • B41M5/00Duplicating or marking methods; Sheet materials for use therein
    • B41M5/50Recording sheets characterised by the coating used to improve ink, dye or pigment receptivity, e.g. for ink-jet or thermal dye transfer recording
    • B41M5/52Macromolecular coatings
    • B41M5/5263Macromolecular coatings characterised by the use of polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • B41M5/5281Polyurethanes or polyureas
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B41PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41MPRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING
    • B41M7/00After-treatment of prints, e.g. heating, irradiating, setting of the ink, protection of the printed stock
    • B41M7/0027After-treatment of prints, e.g. heating, irradiating, setting of the ink, protection of the printed stock using protective coatings or layers by lamination or by fusion of the coatings or layers
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B41PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41MPRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING
    • B41M7/00After-treatment of prints, e.g. heating, irradiating, setting of the ink, protection of the printed stock
    • B41M7/0045After-treatment of prints, e.g. heating, irradiating, setting of the ink, protection of the printed stock using protective coatings or film forming compositions cured by mechanical wave energy, e.g. ultrasonics, cured by electromagnetic radiation or waves, e.g. ultraviolet radiation, electron beams, or cured by magnetic or electric fields, e.g. electric discharge, plasma
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00Flooring
    • E04F15/02Flooring or floor layers composed of a number of similar elements
    • E04F15/04Flooring or floor layers composed of a number of similar elements only of wood or with a top layer of wood, e.g. with wooden or metal connecting members

Abstract

FIELD: construction.
SUBSTANCE: the board consist of a lignocellulose-based bearing material. The bearing material is primed and has a decorative coating applied onto it; the priming layer consisting partly of synthetic resin has surface finish less than 15 mcm.
EFFECT: enhancement of visual attractiveness and aesthetic appeal of board fabricated of lignocellulose-based bearing material due to application of a decorative coating through direct printing; minimisation of the abrasive efforts required for production of smooth glossy surfaces.
29 cl, 5 ex

Description

The invention relates to a method for manufacturing a slab with a decor-containing surface, the slab consisting of a carrier material based on lignocellulosic material, for example a particle board, an OSB board or a fiber board. The invention also relates to a stove with a decor surface and the use of the stove as a floor panel or furniture plate.

According to the state of the art, decorative surfaces on the aforementioned supporting materials are created by coating with sealed papers. In these methods, as a rule, a large number of papers impregnated with a synthetic resin, mainly melamine, melamine carbamide or phenolic resins, are used. At elevated pressure and temperature, they are then pressed either directly (Direct Pressure Laminate (DPL) - direct compression laminate), or only after they are processed into a layered material with a substrate (High Pressure Laminate (HPL) - high pressure laminate or Continous Pressure Laminate (CPL ) - a laminate of continuous production). Decorated papers can have any color scheme and can be sealed with arbitrary decors, such as imitation wood, tile or stone, fancy decor or any possible motifs and patterns.

To increase the abrasion resistance of the surface for the use of coated flooring materials or, for example, for worktops, it may be necessary to strengthen the impregnated papers (laminates) with solid particles in order to achieve an appropriate resistance to surface wear. For this, for example, particles of quartz, nitrides and carbides, including SiO 2 and corundum (α-Al 2 O 3 ), are known. Recently, it has also become known to use the smallest particles of glass or diamond.

This method of creating a decorative surface on a carrier material based on lignocellulosic material, however, is very expensive due to the necessary manufacture of laminates. Therefore, an alternative technique was developed that allows creating a decorative surface on it by directly sealing the carrier material. Sealing of parts is already widely used, to which lesser requirements are imposed on the appearance, as is the case in the manufacture of cabinet rear walls. Developments to create such surfaces also for parts that, on the basis of their exposition in accordance with the subsequent designation must also meet increased aesthetic requirements, have not yet led to satisfactory results, since the desired aesthetic properties, such as sharpness and richness of the printed pattern failed to reach.

According to the prior art, the following layers are applied to create a decorative surface based on a lignocellulosic support material, depending on the intended purpose of the parts and the requirements imposed on their durability, whereby pre-treatment by grinding may precede.

- Primer: as a first treatment step, the surface is usually treated with a primer (adhesion promoter) for subsequent coating. In this case, the primer preferably consists of the same basic components as the subsequently applied layer.

- Fillers: their task is to reduce the absorption capacity of the soil and, in addition, to ensure adhesion with subsequent layers. Depending on the requirements arising from the subsequent field of application of the parts and subsequently applied layers, it may be advisable to apply the filler in two or more operations, between or followed by at least partial curing. The filler serves, in addition, also to fill in irregularities on the surface in order to level it.

- Primer: it is applied after at least partial curing of the filler. The task of the primer, which can also consist of various separate layers with an intermediate or subsequent at least partial curing, is to obtain the main shade prevailing in the decor. For most wood imitations at this stage, mainly coatings with shades from beige to brown or shades of red are applied.

- Ink: depending on the variety of colors of the applied decor and the desired batch size at this stage, using the printing methods known from the prior art, for example, matrix or offset printing, the desired printed pattern is applied. The use of digital printing techniques is also known in this area.

- Finishing: as well as when finishing massive wooden surfaces, here, in comparable ways, surface protection and improved appearance are achieved. The only difference is that here the previously applied decor is covered, and not the pattern of solid wood. Here, therefore, in addition to strengthening the structure of the decoration applied at the previous stage, protection against external influences must also be achieved in order to obtain the desired aesthetic quality during the envisaged service life. Thus, by choosing the appropriate finishing composition, it is possible to achieve the desired degree of surface gloss, a predetermined scratch resistance or a certain abrasion resistance. Depending on various aesthetic properties and expected loads, the number of layers to be applied is selected, which are optionally subjected to intermediate curing in order to ensure partial crosslinking consistent with the subsequent steps. Most of the radiation curable systems used here can also contain particulate matter to achieve high abrasion resistance. Here, it is also possible to disperse the particles over an as yet uncured or already partially cured layer to achieve the desired abrasion resistance. By choosing different particle sizes in or on different layers, their application can be optimized; for example, it was favorable to select small particle sizes in or on the other of the upper layers to achieve high abrasion resistance. Other additives, for example, the so-called UV absorbers, which form an increased protection against UV radiation and thus prevent unwanted premature yellowing, may be contained in the finishing composition in order to achieve the desired aesthetic properties and to obtain them during the intended service life.

In order to achieve the desired smoothness of the final product, a layer provided for subsequent grinding can be applied between the finishing layers.

For surface structuring, embossing with a structured pressing plate or structured roller of the corresponding recesses matching the previously applied decor is also possible before final curing in order to better simulate the material reproduced by the decor with the finished product. Another possibility of obtaining such a structure, also called “synchronous pores” or “real pores”, is to achieve various applied amounts of subsequent coatings in different color zones using printing inks with different wetting properties. Thus, the desired structure can be obtained depending on the decor. This structuring can also be called "chemical pores."

The systems used may be based on organic solvents or may also be water-based. To cure the various layers, in agreement with the coating materials used, elevated temperature, UV radiation, ionizing radiation, such as, for example, electron beams, or other methods and devices known for these purposes, individually or in combination, can be used.

The advantage of sealing the plates instead of covering them with a laminate is that the anti-tension layer on the back of the plate can be avoided. Due to this, it is possible to reduce production costs.

However, there is a drawback inherent in all the known execution options, however, that in order to achieve high print quality, lignocellulosic materials based carrier materials have an insufficiently uniform surface or an evenness that / can also cause “shagreening” of previously applied layers, t .e. their structure caused by their very application. As a result, slightly different conditions arise at the point of contact with the printing plates or the printing cylinders. Despite the use of appropriately designed backpressure devices, it is therefore impossible to achieve clearly defined areas of decor, which is why it is impossible to achieve the desired clear boundaries of the printed pattern and the desired print quality. Also, the creation of an extremely uniform and even surface by means of complex preliminary processing of the carrier material based on lignocellulosic material with the most diverse, for the most part very sophisticated methods could not lead to the desired result. The reason for this deteriorated print quality also lies in the “shagreening” of the varnish itself, i.e. the structure of the applied layers, due to the application itself.

The quality of the printed pattern is deteriorating, in particular, also due to the fact that the surface roughness leads to erosion of individual points of the pattern. Even if printing was carried out, for example, with a resolution of 54 dots / cm or 2916 dots / cm 2 , the picture shows a lower resolution, since the points of the picture are not clearly separated from each other.

Another drawback of the previous printing technique is that the mostly UV cured varnishes used for primers and coatings are expensive in and of themselves. In addition, a UV emitter is required to cure various varnish layers. Production costs are therefore significant.

Finally, another drawback is that the lacquer layers must be sanded, due to which expensive material is removed, and there is a significant amount of dust that must be reliably sucked off inside the unit and removed.

The invention is therefore based on the technical task of creating a method by which it would be possible to obtain decorative surfaces with improved aesthetic properties on plates of lignocellulosic material based on a carrier material by direct sealing. The aim of the invention is to create aesthetic properties of such quality that the manufactured plates can also be used in areas that, due to their exposure, must meet increased aesthetic requirements.

Another technical challenge is to completely or partially avoid varnish coatings in order to minimize production costs.

Another technical problem is, finally, to minimize the grinding processes necessary for the previous receipt of varnished surfaces or to completely avoid them, in particular, with the applied UV-cured varnish layers.

The stated technical problems are solved, according to the invention, by means of methods with the features of claims 1, 22, 31 of the formula. In the same way, the technical problem is solved by means of plates according to items 37-39,45, as well as their application according to items 52, 53. Other variants of this method are given in the corresponding dependent paragraphs.

In order to obtain the necessary basis for an optimal printed pattern according to the invention, before surface sealing of the lignocellulosic carrier material, the surface is smoothed using a smoothing device. After priming, the smoothing device evens out any possible surface irregularities after priming, resulting in an optimally even surface.

This can prevent possible protruding fibers from the primer or the so-called turbidity that occurs in the final product due to different thicknesses of coatings before printing, which occurs due to uneven coloring of the printed surface, i.e. due to the transmission of the base. Printed soil, i.e. the primed surface is therefore distinguished by its better suitability to achieve high print quality, which, in addition to uniformity and reproducibility, also manifests itself in particularly high definition and richness of the printed pattern.

As a measure of the clarity of the printed pattern, the resolution achieved by the method according to the invention is greater than 54 dots / cm or 2916 dots / cm 2 , in particular ≥60 dots / cm or 3600 dots / cm 2 . In particular, a resolution of ≥70 dots / cm or 4900 dots / cm 2 can be achieved.

Preferred when implementing the method according to the invention, is that smoothing is carried out shortly before sealing, i.e., in particular, for a period of time less than 1 minute, preferably less than 10 seconds and preferably less than 5 seconds before sealing.

Especially suitable for smoothing before sealing were devices operating on the principle of an iron and having a contact surface. In addition to mechanical contact, a certain temperature is also applied to the surface.

Contact between the smoothed and contact surfaces occurs in a preferred manner over the entire area. Therefore, the entire surface to be smoothed is brought into contact with the contact surface. Moreover, it is preferable that the entire surface is brought into contact with the contact surface evenly.

The contact surface in the first embodiment is substantially flat so that at least each flat surface portion is in contact with the contact surface. This method is therefore preferred in a clock manner.

This can also be done by means of a roller arranged so that the surface to be coated immediately before printing comes into contact with it along the contact line. As a result of continuous movement, the surface is therefore completely smoothed. Such a technique is preferred in continuous processes.

Such a roller can be driven into rotation by means of suitable drive means, for example, by means of an engine, and due to a passing or counter rotation to make a movement relative to the surface to be treated. In the same way, the roller can move so that there is no relative motion between its surface and the surface of the plate.

Another way to achieve the desired “iron effect” is to tilt the tempered roller so that its axis of rotation passes at a different angle from the direction of motion of the workpiece. This can achieve the relative motion of the surfaces in contact, which, depending on the degree of deviation of the axis of rotation, will be different. The resulting abductions due to the inclined position of the roller should be taken into account when transporting the slab.

A similar action can be achieved with the help of rollers oscillating along the axis. This, in particular, in interaction with the rotation of the roller increases the smoothing uniformity. In this case, forced plate driving is preferable in order to ensure controlled plate driving and to prevent its slipping.

The applied pressure exerted by the smoothing device on the surface to be treated is preferably kept constant during the process. For this, the pressing force is coordinated, at least depending on the implementation of the smoothing device, the selected relative speed between the smoothing device and the plate, the type of carrier material, the composition of the primer and the feed rate. Proven combinations of these parameters can be recorded in memory, due to which, when changing the feedrate or other parameter, all other parameters can be automatically matched.

In addition, the execution of the contact surface of the smoothing device also has an effect on the smoothing result. In addition to polished metal materials, coated metals can also be used, with Teflon-based plastics being suitable as coatings. Hard chrome or nickel plated metal surfaces or plastics or a plastic coating may also be used. Thus, a high surface smoothness is obtained with favorable thermal properties, thereby achieving a good “iron effect”.

The smoothness of the surface of the smoothing tool can be characterized with roughness values of 0.06-6 microns.

As tests have shown, achieving good smoothing is not necessarily related to the smoothness of the contact surface of the smoothing device. When using metals, tests were carried out with structured or microstructured surfaces, which in part were able to give at least the same good results. In this case, any regular or irregular linear patterns with intermediate recesses are considered as a surface structure. The structure may have a depth or amplitude of about 0.5 mm.

Also, by wetting the smoothing device with water or liquids containing matched additives, effects that optimize the smoothing process can be achieved.

In order to achieve higher feed rates for a better use in a coating plant with a smoothing device, it may be advisable to arrange several smoothing devices one after the other to achieve the desired surface quality before the printing step.

The invention has been described above with respect to smoothing one or more layers. Below is described in detail another aspect of the invention, which is independent of smoothing and also improves the quality of the varnished board. In this case, it is a question of replacing one or more of the primer, color and / or varnish layers with a synthetic resin, preferably consisting of a polyurethane-based synthetic resin system.

The above technical problem is also solved, according to the invention, also by a method of manufacturing a plate with a decor surface, the plate consisting of a carrier material based on lignocellulosic material, in which the decor surface is primed with at least one primer layer, the primed surface is sealed to create a decor , the sealed surface is finished with at least one finishing layer and at least one primer layer is applied as a synthetic resin layer.

Using this method, it was possible to achieve particularly good results, in particular when smoothing the primer layer. Instead of a primer varnish, a synthetic resin system is used. Due to the achieved higher layer thicknesses and improved adhesive properties of this type of primer, it was possible to abandon the generally accepted use of filler and primer, as well as UV-curable varnishes. The resulting cost savings are significant. In addition to the significantly smaller size of the production plant, by reducing the number of processing steps, cost savings are achieved due to cheaper substances.

Values of 40-100 g / m 2 are considered as applied amounts. The exact amounts applied depend on the surface to be coated and the synthetic resin used. Preferably, a polyurethane-based synthetic resin system is applied as a synthetic resin. This type of synthetic resin system is known and has already established itself in other applications. Other systems, for example, based on epoxy or polyester resins, can also be used as a synthetic resin system. In general, the synthetic resins used can also be characterized in such a way that both thermoplastic and thermosetting synthetic resins are considered.

In some applications, it has been found to be preferable that an adhesion promoter is applied to the surface to be printed on at least one primer layer of synthetic resin. Due to this, it was possible to improve the bond of the synthetic resin with the surface of the carrier material.

One advantage of using a synthetic resin system for a primer layer is that the synthetic resin layer itself can be matched in color to the primer color achieved. Thus, in one operation, a finished primer is obtained for subsequent printing of the decor.

In some cases, the staining of synthetic resin is difficult to adjust. In these cases, it is preferable if, after the primer layer of synthetic resin, an additional primer layer of a primer consisting of a paint varnish is applied. This application can be more reliable and, possibly, also cheaper than painting the synthetic resin itself. In each case, it should be determined whether it is preferable to paint the synthetic resin itself or to apply an additional coloring varnish.

Another advantage of using a synthetic resin layer as a primer is that the synthetic resin can be smoothed in a simple manner. For smoothing, one can apply the method of smoothing the primer consisting of varnish as described above.

The above technical problem is solved, according to the invention, also by a method of manufacturing a plate with a decor surface, the plate consisting of a carrier material based on lignocellulosic material, in which the surface supplied with the decor is primed with at least one primer layer, the primed surface is sealed to create a decor , the sealed surface is finished with at least one finishing layer and at least one finishing layer is applied as a layer of synthetic resin.

It also turned out to be preferable for the finish layer to be made from synthetic resin. Since the cured synthetic resin layer has good abrasion resistance and hardness values, expensive UV cured varnishes containing micro- or nanoparticles can be largely avoided by using the synthetic resin layer as a finishing layer.

In this case, values of 40-100 g / m 2 are considered as applied amounts. The exact amounts applied depend on the surface to be coated and the synthetic resin used.

The finishing layer further includes the fact that its abrasion resistance can be improved by the addition of particles, for example corundum, silicon oxide or glass.

Another advantage is that the grinding processes necessary when using varnishes are excluded both in the manufacture of the primer layer and in the manufacture of the finishing layer. The synthetic resin layer can be smoothed out without subsequent grinding so that the resulting surface meets the requirements. The absence of grinding processes means, in particular, for the method a significant advantage, since the dust that does not have to be removed and disposed of, and the loss of material that occurs during grinding is completely eliminated. In particular, grinding varnishes led to the loss of expensive material, which can be completely avoided by the invention.

In special cases, it turned out to be preferable that before applying at least one finishing layer of synthetic resin, a particle-containing lacquer layer, preferably containing corundum particles, is applied to the sealed surface. The advantage of lowering production costs in this case is partially lost, but the abrasion resistance is increased, so that the method is also suitable for the manufacture of boards with particularly high requirements. The lacquer layer does not need to be sanded before applying a layer of synthetic resin. The lacquer layer is preferably subjected to UV curing. In addition, the varnish layer contains particles with an average size of 1-100 microns.

In one preferred embodiment, after applying at least one finishing layer of synthetic resin, a varnish layer is applied, cured predominantly by UV radiation and containing, in particular, particles of medium size from 100 nm to 1 μm (nanoparticles). The particles are preferably composed of mineral-based materials, such as silicic acid, or glass. In this case, we are talking, therefore, about the so-called nano-varnish. Also, this variant of the method turned out to be preferable for applications with particularly high requirements, although the advantage of reducing production costs is partially lost.

Another variant of the method is that the surface of the finishing or varnish layer is provided with a surface structure. Thus, in particular, it is possible to create a surface structure that matches the decorative pattern. This allows, for example, to simulate the natural texture of wood, if the optical pattern matches the tangible pattern.

The above technical problem is solved, according to the invention, also by means of a plate with a carrier material based on lignocellulosic material, having a primer layer with a surface and decor printed on the primer layer, the primer layer having a microroughness height of less than 15 μm. Preferred microroughness heights of less than 10 microns, and in this case, increased requirements for smoothing tools and their use. With particularly good tuning, even a microroughness of 6-8 microns can be achieved.

This small microroughness height can be obtained, in particular, by the smoothing method described above, also related to the invention. The small height of the microroughness ensures the previously unattainable quality of the printed pattern.

The above technical problem is solved, according to the invention, also by means of a plate with a lignocellulosic material-based carrier material having a primer layer with a surface and decor printed on the primer layer, the print pattern having a resolution of more than 54 dots / cm, in particular ≥60 dots / cm preferably ≥70 dots / cm.

High print quality can be achieved, in particular, by applying the method described above. In particular, print quality can be achieved by the small surface roughness of the primer layer described above.

Further, the above technical problem is solved, according to the invention, also by means of a plate with a lignocellulosic material-based carrier material having a primer layer with a surface and decor printed on the primer layer, the primer layer at least partially consisting of synthetic resin. The synthetic resin preferably consists of a polyurethane-based synthetic resin system.

This multilayer structure excludes, firstly, a number of operations in the manufacture of the slab. Secondly, the old expensive materials are replaced by cheaper ones.

To increase the adhesion of the synthetic resin to the carrier material, a layer consisting of an adhesion promoter is preferably located between it and the primer primer layer consisting of synthetic resin.

In addition, the primer layer consisting of synthetic resin can be matched in color to the primer color obtained. This allows direct sealing of the primer layer without the need for an additional layer. This, however, is possible if the synthetic resin can be painted in the desired color.

If this cannot be ensured, then it is provided that a primer consisting of varnish is located on the primer layer consisting of synthetic resin. A primer consisting of a traditional primer can be simply matched to the desired shade of color.

It is further preferred that the primer layer consisting of synthetic resin has a microroughness height of less than 15 microns, in particular less than 10 microns, preferably 6-8 microns. In this case, high print quality can be achieved, which provides an improved and, thus, even more natural imitation of motifs.

The above technical problem is solved according to the invention, in addition, also by means of a plate with a lignocellulosic material-based carrier material having a primer layer with a surface printed on the primer layer with a decor and a decoration layer applied to the printed decor, the finish layer being at least partially composed of synthetic resin. Also here, the synthetic resin preferably consists of a polyurethane-based synthetic resin system.

Thus, according to the invention, it was found that not only the primer layer, but also the finishing layer may consist of a synthetic resin system. It was found that the hardness and abrasion resistance of the synthetic resin is sufficient for a number of plate applications without the need for UV-curable finishes. For many applications of these properties is enough, and you can reduce the manufacturing costs for the manufacture of plates.

If the requirements for the properties of the finishing layer are higher than the finishing layer consisting of synthetic resin can meet, it turned out to be preferable if between the printed decorative layer and the finishing layer consisting of synthetic resin there is a lacquer layer containing particles, in particular a lacquer layer containing corundum particles. This varnish layer contains mainly particles with an average size of 1-100 microns. Larger particles are also possible.

Also, a particle-containing lacquer layer can be arranged on the finishing layer consisting of synthetic resin, and also here the lacquer layer is configured to cure with UV radiation. Preferably, the lacquer layer contains particles with an average size of from 100 nm to 1 μm. Due to this additional layer, it is possible for special applications to increase the surface hardness and abrasion resistance.

Also, in this embodiment, it is preferable if the surface of the finishing or varnish layer has a surface structure. Thus, also in this case, it is possible to achieve a match between the optical and tangible patterns.

Above, a number of embodiments of the invention have been illustrated by examples of methods and plates made by them. The plates themselves can have a variety of uses. However, it is preferable to use the plates either for the floor panel or for the furniture part. In both applications, we are talking about special surface properties that can be obtained in a preferred way thanks to the invention.

The following are examples of methods and plates made by them.

Example 1. The manufacture of the floor panel with smoothing the primer

For the manufacture of the floor panel, an already polished medium density fiberboard (MDF board) with a thickness of 5.8 mm and a density of 660-900 kg / m 3 is introduced into the installation, on which primers, fillers, primers, printing inks and finishes can be sequentially applied . Behind the brush section, where possible contaminants or grinding dust is removed, by means of rollers, in the first stage, a filler is applied in an amount of about 15 g / m 2 , and in the second stage, in an amount of about 25 g / m 2 , and intermediate drying always follows. A primer with the main shade of the desired decor is rolled onto the carrier material obtained in this way in one or two stages, the primer being applied in an amount of about 15 g / m 2 , respectively, and after each application, partial drying follows.

Now, at a feed rate of, for example, 32 m / min, polishing steel rollers tempered to 160 ° C with a relative speed of 0-10 m / min and a clamping force of 50-100 N / m across the width of the plate carry out the smoothing process. Thus processed, the plate has a surface that is even in color, structure and degree of gloss throughout its area. No fibers protruding from the substrate into the coating film are also visible. In this case, the fibers after smoothing can still lie noticeably on the surface.

Immediately after the smoothing device, using three printing devices made of a printing cylinder with colorful and moisturizing rollers and a rubberized cylinder with a counter-pressure cylinder, wood decor is printed. This method is called indirect gravure printing. Other printing methods, such as offset, can also be used.

As a finish of the obtained surface, a UV curable varnish system is applied in three parts. The first part consists of two corundum-containing layers with an applied amount of about 35 g / m 2 , respectively, followed by intermediate curing. A corundum-containing UV-curable varnish is then applied, which, after intermediate curing and subsequent intermediate grinding with 280-320 grit, causes additional surface leveling.

The final part of the finish is then formed by a UV curable varnish layer with a quantity of, for example, 7 and 8 g / m 2 , which is also applied in two stages and equipped with corundum particles, and the corundum particles contained here are, on average, smaller than the particles of the previous varnish layers. Also here, each applied layer is followed by an intermediate cure. If necessary, this step may be followed by embossing of the surface profile.

At the final final curing of the applied structure, the final crosslinking of the various components occurs.

The resulting plates after a holding time of about a day to equalize the temperature and for curing are cut in the traditional way on the panel, equipped with edge profiles and packaged.

The resulting floor panels are characterized by a uniform juicy pattern and precise contrasts of the decor.

When tested by the methods specified in prEN 14354 (2001) “Wood-based materials - veneered flooring”, it was possible to fulfill the criteria for bursting resistance, swelling in thickness, impact resistance, wear resistance, scratch resistance and chemical resistance with the possibility of referring made thus floor panels to load class 31 (suitable for moderate loads in commercial premises). For laminate floors, the prEN 13329 standard can also be met at least partially. For example, cigarette ash resistance requirements are not met.

Example 2. The manufacture of furniture plate with smoothing the primer

For the manufacture of a working plate for office premises, a polished chipboard with a thickness of 24 mm and a density of 590 kg / m 3 is coated with a pigmented hot melt adhesive by rolling.

After intermediate curing in a smoothing device, the contact surface of which here consists of a Teflon-coated steel roller, which moves along its longitudinal axis with 12 short strokes (about 4 cm) per second at a relative speed of 33 m / s (corresponding to a roller with a diameter of 350 mm approximately rotational speed 1800 min ' 1 ) counter-current and with a clamping force of 180 N / m, smoothing takes place and, thereby, obtaining the desired optimal printing soil.

Subsequent sealing of the plate occurs in the device described in example 1. To protect the applied decor, here, due to reduced requirements for abrasion resistance, only two UV curable are applied containing abrasion resistant particles of the lacquer layer with an applied amount of 15 g / m 2 , respectively, which are subjected to intermediate curing after application.

Before the final final curing of the coating, the plate with the embossing roller is also provided with a structure that should cause a lower degree of gloss so that fingerprints expected on the surfaces of office furniture are optically less visible. The degree of gloss can also be controlled chemically in the varnish itself. The embossing roller can be used, for the rest, also to perform surface profiling in order to achieve a profiling matching the decor.

The resulting decorative surface of the thus treated board is characterized by a high-quality decor pattern at lower production costs compared to the traditional laminate coating.

Example 3. The manufacture of a plate with a primer of synthetic resin

For the manufacture of a plate that can be used, for example, as a floor panel, an already polished medium density fiberboard (MDF board) with a thickness of 5.8 mm and a density of 660-900 kg / m 3 is introduced into the installation, on which applied primer, printing ink and finishing composition. Behind the brush section, where possible contaminants or grinding dust is removed, the primers from the synthetic resin system on a polyurethane basis in an amount of about 70 g / m 2 are applied by means of rollers. The primer is applied in the heated state.

The synthetic resin is painted before application so that the resulting primer layer is suitable for direct sealing.

In further tests, it turned out as an advantage that the applied primer layer was first only partially cooled and smoothed by means of a smoothing device.

To do this, at a feed rate of, for example, 32 m / min using tempered to 160 ° C, polished steel rollers with a relative speed of 0-10 m / min and a clamping force of 50-100 N / m across the width of the plate, a smoothing process is carried out. Thus processed, the plate has a surface that is even in color, structure and degree of gloss throughout its area. No fibers protruding from the substrate into the coating film are also visible. Then, with or without smoothing, the synthetic resin layer is completely hardened by cooling. In this case, curing can also be achieved through the use of rays.

Directly after the smoothing device, wood decor is printed by means of three printing apparatuses made of a printing cylinder with colorful and moisturizing rollers and a rubberized cylinder with a counter-pressure cylinder.

As a finish of the obtained surface, a UV curable varnish system is applied in three parts. The first part consists of two corundum-containing layers with an applied amount of about 35 g / m 2 , respectively, followed by intermediate curing. A corundum-containing UV-curable varnish is then applied, which, after intermediate curing and subsequent intermediate grinding with 280-320 grit, causes additional surface leveling.

The final part of the finish is then formed by a UV curable varnish layer with a quantity of, for example, 7 and 8 g / m 2 , which is also applied in two stages and equipped with corundum particles, and the corundum particles contained here are, on average, smaller than the particles of the previous varnish layers. Also here, each applied layer is followed by an intermediate cure. If necessary, this step may be followed by embossing of the surface profile.

At the final final curing of the applied structure, the final crosslinking of the various components occurs.

The resulting floor panels are characterized by a uniform juicy pattern and precise contrasts of the decor.

Example 4. The manufacture of panels with a finish of synthetic resin

For the manufacture of a plate that can be used, for example, as a floor panel, an already polished medium density fiberboard (MDF board) with a thickness of 5.8 mm and a density of 660-900 kg / m 3 is introduced into the installation, on which applied primer, filler, primer, printing ink and finishing composition. Behind the brush section, where possible contaminants or grinding dust is removed, by means of rollers, in the first stage, a filler is applied in an amount of about 15 g / m 2 , and in the second stage, in an amount of about 25 g / m 2 , and intermediate drying always follows. A primer with the main shade of the desired decor is rolled onto the carrier material obtained in this way in one or two stages, the primer being applied in an amount of about 15 g / m 2 , respectively, and after each application, partial drying follows.

Now, at a feed rate of, for example, 32 m / min, polishing steel rollers tempered to 160 ° C with a relative speed of 0-10 m / min and a clamping force of 50-100 N / m across the width of the plate carry out the smoothing process. Thus processed, the plate has a surface that is even in color, structure and degree of gloss throughout its area. No fibers protruding from the substrate into the coating film are also visible. In this case, the fibers after smoothing can still lie noticeably on the surface.

Directly after the smoothing device, wood decor is printed by means of three printing apparatuses made of a printing cylinder with colorful and moisturizing rollers and a rubberized cylinder with a counter-pressure cylinder.

As a finish of the obtained surface, a finishing layer consisting of a system of synthetic resin on a polyurethane base is applied by means of rollers. The applied amount is 70 g / m 2 .

During application, the polyurethane-based synthetic resin is heated to provide a suitable finish.

In further tests, it turned out to be an advantage that the applied finishing layer was first only partially cooled and smoothed by means of a smoothing device.

For this, at a feed rate of, for example, 32 m / min using tempered to 160 ° C, polished steel rollers with a relative speed of 0-10 m / min and a clamping force of 50-100 N / m across the width of the plate, a smoothing process is carried out. Thus processed, the plate has a surface that is even in color, structure and degree of gloss throughout its area. No fibers protruding from the substrate into the coating film are also visible.

Then, with or without smoothing, the synthetic resin layer is completely hardened by cooling.

The resulting plates are distinguished by a uniform juicy pattern and precise contrasts of the decor.

Example 5. The manufacture of a plate with a primer of synthetic resin and with a finish of a layer of synthetic resin

For the manufacture of a plate that can be used, for example, as a floor panel, an already polished medium density fiberboard (MDF board) with a thickness of 5.8 mm and a density of 660-900 kg / m 3 is introduced into the installation, on which applied primer, printing ink and finishing composition. Behind the brush section, where possible contaminants or grinding dust is removed, the primers from the synthetic resin system on a polyurethane basis in an amount of about 70 g / m 2 are applied by means of rollers. The primer is applied in the heated state.

The synthetic resin is painted before application so that the resulting primer layer is suitable for direct sealing.

In further tests, it turned out as an advantage that the applied primer layer was first only partially cooled and smoothed by means of a smoothing device.

For this, at a feed rate of, for example, 32 m / min using tempered to 160 ° C, polished steel rollers with a relative speed of 0-10 m / min and a clamping force of 50-100 N / m across the width of the plate, a smoothing process is carried out. Thus processed, the plate has a surface that is even in color, structure and degree of gloss throughout its area. No fibers protruding from the substrate into the coating film are also visible.

Then, with or without smoothing, the synthetic resin layer is completely hardened by cooling.

Directly after the smoothing device, wood decor is printed by means of three printing apparatuses made of a printing cylinder with colorful and moisturizing rollers and a rubberized cylinder with a counter-pressure cylinder.

As a finish of the obtained surface, a finishing layer consisting of a system of synthetic resin on a polyurethane base is applied by means of rollers. The applied amount is 70 g / m 2 .

During application, the polyurethane-based synthetic resin is heated to provide suitable processing.

In further tests, it turned out to be an advantage that the applied finishing layer was first only partially cooled and smoothed by means of a smoothing device.

For this, at a feed rate of, for example, 32 m / min using tempered to 160 ° C, polished steel rollers with a relative speed of 0-10 m / min and a clamping force of 50-100 N / m across the width of the plate, a smoothing process is carried out. Thus processed, the plate has a surface that is even in color, structure and degree of gloss throughout its area. No fibers protruding from the substrate into the coating film are also visible.

Then, with or without smoothing, the synthetic resin layer is completely hardened by cooling.

The resulting plates are distinguished by a uniform juicy pattern and precise contrasts of the decor.

Claims (29)

1. A method of manufacturing a plate with a decor, in particular wood decor, the surface, and the plate consists of a carrier material based on lignocellulosic material, in which the surface supplied with the decor is primed, the primed surface is smoothed without grinding, so that the primed surface has a microroughness height of less than 15 microns , the smoothed surface is sealed to create a decor by means of printing cylinders, a printed pattern is applied with a resolution of at least 60 dots / cm, preferably at least least 70 points / cm, and after the sealing surface of the trim.
2. The method according to claim 1, in which the smoothing of the primed surface is carried out for a period of time less than 1 min, preferably less than 10 s before sealing.
3. The method according to claim 1, wherein the primed surface is smoothed by contact with at least one tempered surface of the smoothing device.
4. The method according to claim 3, in which the surface of the entire area is brought into contact with a tempered contact surface.
5. The method according to claim 3, wherein the tempered contact surface is formed by means of a surface of a substantially flat plate.
6. The method according to claim 3, in which the tempered contact surface is formed by means of the surface of at least one roller.
7. The method according to claim 6, in which by rotating the roller create relative motion between the smoothed surface and the contact surface of the roller.
8. The method according to claim 7, in which the axis of rotation of the roller is oriented at an angle to the direction of movement of the surface.
9. The method according to claim 6, in which the roller is driven in an oscillating motion in the longitudinal direction.
10. The method according to claim 3, wherein the tempered contact surface is pressed against the surface.
11. The method of claim 10, wherein the tempered contact surface is pressed against the primed surface along the width of the plate with a clamping force in the range of 50-100 N / m.
12. The method according to claim 3, in which a smooth, in particular polished, contact surface is used.
13. The method according to claim 3, in which a structured, in particular microstructured, contact surface is used.
14. The method according to claim 3, in which the contact surface consists of metal.
15. The method according to claim 3, in which the contact surface consists of coated, in particular coated with Teflon, metal.
16. The method according to claim 3, in which the contact surface consists of plastic, in particular coated with Teflon.
17. The method according to claim 3, wherein the contact surface is wetted with liquid.
18. The method according to 17, in which the contact surface is wetted with water or a liquid containing additives.
19. The method according to one of claims 1 to 18, wherein a filler is applied to the surface to be primed before the primer.
20. The method according to one of claims 1 to 18, in which the sealed surface is covered with a primer layer consisting at least partially of synthetic resin.
21. A slab, in particular for use as a floor panel or furniture plate, with a lignocellulosic material-based carrier material containing a primer layer, a surface printed on the primer layer by printing cylinders with a decor and a decoration layer applied to the printed decor, characterized in that the primer the layer has a microroughness height of less than 15 microns, while the printed pattern has a resolution of at least 60 dots / cm.
22. The plate according to item 21, wherein the primer layer and / or the finishing layer at least partially consists of synthetic resin, while between the printed decor and the finishing layer there is a lacquer layer containing particles.
23. The plate according to item 22, wherein the varnish layer contains corundum particles.
24. The plate according to item 22, wherein the synthetic resin of the finishing layer consists of a synthetic resin system on a polyurethane basis.
25. The plate according to item 22, wherein the varnish layer contains particles with an average size of 1-100 microns.
26. The plate according to item 21, wherein the lacquer layer containing particles is located on the finishing layer.
27. The plate according to p, characterized in that the varnish layer contains particles with an average size of from 100 nm to 1 μm.
28. The plate according to one of paragraphs.23-27, characterized in that the surface of the finishing layer or the surface of the lacquer layer has a surface structure.
29. The plate according to one of paragraphs.21-27, characterized in that the primer layer has a microroughness height of less than 15 microns, in particular less than 10 microns, mainly 6-8 microns.
RU2007103011/12A 2004-07-01 2005-06-30 Method of manufacturing structural boards such as floor panels and furniture boards and board proper RU2344940C2 (en)

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UA87315C2 (en) 2009-07-10
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AT463351T (en) 2010-04-15

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